Cast Resin Transformer

federal transformers Co. L.L.
C
DRY TYPE CAST RESIN TRANSFORMER
federal transformers Co. L.L.C

1. Description
A Dry Type Transformer is defined as a
Transformer in which the core and windings
are not immersed in an insulating liquid.
A Dry Type Transformer having one or more
windings encapsulated in solid insulation is
called an encapsulated winding dry type
transformer.

2. Standards
IEC 60076 11 & ANSI C57.12.01
3. What is Casting
The essential feature of Dry Type Cast Resin
Transformer is the use of metal mould, which is
essential to hold the epoxy in position during
filling, gel and cure cycles.
A Vacuum filling process is essential to eliminate
the formation of voids and trapped gases in the
casting. If a metal mould is not used, the epoxy
will run and drain during the curing cycle.

4. Resin System
A Resin System used in the casting is a precisely
designed and controlled mixture of
Epoxy Resin Bisphenol based

Hardner Acid unhydryde
Accelerator Tertiary amine
Plasticiser
Filler
The reaction of the epoxy resin with the hardener

is with very little rearrangement of the chemical
chain and volatile or toxic products are not
produced in the reaction

5. Special Properties Of The Resin System
Low Viscosity
Quick & Easy Curing
Low Shrinkage
High Adhesive Strength
High Mechanical Strength
Good Electrical Properties

6. Manufacturing Process
Winding
Mould Assembly
Preheating
Casting
Curing
Finishing & Testing of Coils

7. Core
The core construction is similar to the core
construction of oil filled transformers, except
for the fact that assembled corers are treated
with an anticorrosive paint for protection
against weather, dust, exposure etc.

8. The Core & Winding Assembly
The core and coil assembly is designed with
due consideration for absorbing the axial
unbalanced forces due to short circuit and
also to reduce noise level.
A resilient coupling between winding and core
is given to absorb the stresses during thermal
and short circuit conditions. The spring
coupling is designed such that resonance is
avoided

9. Enclosure
Enclosure design depends on application. IP 21
protection is generally used for indoor
application. The ventilation design is done with
due consideration of the airflow requirement
and heat transfer.
Enclosure of other classes, cooling fans for
enhancing capacity etc. can be provided as per
specific requirements.

10. Advantages of Cast Resin Transformers
10.1 Non Hygroscopic Insulation
The cast resin transformer is non hygroscopic
and hence will not absorb moisture during
service or when stored, whereas oil filled
transformer has high affinity to moisture
Cast Resin Transformer can be immediately
switched on even after long storage.

10.2 Non Flammable
Cast Resin Transformers are non flammable
and will not explode or produce toxic gases.
An internal fault in a liquid filled
transformer can cause a fire and explosion
because its thermal energy balance is positive,
whereas, cast resin transformer has nearly
negative thermal energy balance

Relative value of total flammable material in
different type of transformers
Oil Filled Transformer 100
Silicone Liquid Filled Transformer 88
Synthetic Liquid Filled Transformer 63
Cast Resin Transformer 24
10.3 Very High Short Circuit Strength
Cast Resin Transformer has very high
mechanical strength when compared to oil filled
transformers. This is of importance because
statistics shows that majority of the failures is
due to short circuit.

10.4 No Pilferage or Leakage of oil
Leakage/pilferage of oil/insulation liquid is a
general problem associated with oil filled
transformer and cast resin transformers do not
have these problems.
10.5 Maintenance Free
Once installed, the cast resin transformers require
practically no maintenance and this saves
operating cost.

10.6 Protection against Corrosive atmosphere
The resin casting are impervious to most common
gases, chemical fumes etc and are best suitable for
industrial applications
10.7 Partial Discharge Free
The transformers are partial discharge free at
normal working conditions.
10.8 Saving of Installation space and cost of LV
cable
The cast resin transformer can be used in basement
of building or very near the load depending on the
application. This gives the following advantages.

Saving in cost of land. (separate outdoor
substation is required, if oil filled transformer is
used.)
Saving in LV cables because the transformer
can be placed near the load center basement
etc.
10.9 - Cast resin transformers can allow high
temperature rise upto 100C for Class F and
higher temperature for class H & class C. Thus
the transformers can be accommodated at
locations
where
there
are
dimensional
limitations space restrictions etc.

11. Extensive use of Cast Resin Transformers
China
Europe
U.S.A
Middle East
Japan
Taiwan
India Increased usage started now

12. Applications
High Rise Buildings
Air ports
Shopping Malls
Cinema Halls
Airports
Hospitals
Generating Stations
Factories etc.

Installed Annual Production Capacity 1,200 MVA
Ratings upto 5,000kVA 36kV Class

Supply Record of Federal Transformers Co. L.L.C
make Dry Type Cast Resin Transformers
Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
1.
Electromechanical Est.
Abu Dhabi
1500
11/0.433
31.12.2000
2.
Electromechanical Est.
Abu Dhabi
1500
11/0.433
27.02.2001
3.
Hi Al Nuaimi Electricals,
RAK
1000
6.6/0.390
07.06.2002
4.
Drake & Scull, Abu Dhabi
1500
11/0.415
06.08.2002
5.
Gulf Contractors, Abu

Dhabi
1500/2000
11/0.433
08.08.2002
6.
2500/3300
11/3.3
15.10.2002
7.
1500/2000
3.3/0.433
15.10.2002
8.
Aster, Abu Dhabi
1500
11/0.433
08.12.2002
9.
Petron, Abu Dhabi
1500
11/0.433
25.01.2003
10.
Mapco, Abu Dhabi
1500
11/0.433
27.05.2003

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
11.
Mapco, Abu Dhabi
1500
11/0.433
13.08.2003
12.
Aster, Abu Dhabi
1500
11/0.433
13.08.2003
13.
Thermo, Abu Dhabi
1500
11/0.433
07.09.2003
14.
Aster, Abu Dhabi
1500
11/0.433
03.03.2004
15.
Group 3, Abu Dhabi
1500
11/0.433
22.05.2004
16.
16.
Al Sabbah, Abu Dhab
1500
11/0.433
22.07.2004
17.
Al Meraikhi, Abu Dhabi

Dhabi
1500
11/0.433
25.08.2004
18.
Gulf Lights, Qatar
1000
11/0.433
30.09.2004
19.
ETA Power Projects, Abu

Dhabi
1000
11/0.415
11.10.2004
20.
Trane, Sharjah
1500
11/0.400
27.11.2004
21.
Al Nasser Investments,
Abu Dhabi
1500
11/0.433
01.12.2004

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
22.
Gulf Lights, Qatar
500
11/0.433
13.02.2005
23.
Bahwan Engineering,
Oman
1600
11/0.400
17.02.2005
24.
EDT, Australia
750
11/0.433
12.07.2005
25.
Emirates Technical
Associates, Abu Dhabi
1000
11/0.415
31.08.2005
26.
ABB, Abu Dhabi
1000
11/0.415
27.10.2005
27.
Gulf Lights, Qatar
1000
11/0.433
07.03.2006
28.
Hyundai, Abu Dhabi
1000
11/0.415
09.03.2006
29.
Arabian Construction, Abu

Dhabi
1500
11/0.433
25.03.2006
30.
ADWEA, Abu Dhabi
1000
11/0.433
28.03.2006
31.
ADWEA, Abu Dhabi
1000
11/0.433
14
22.04.2006

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
32.
ADWEA, Abu Dhabi
1500
11/0.433
14
23.04.2006
33.
ADWEA, Abu Dhabi
1500
11/0.433
16
09.05.2006
34.
ADWEA, Abu Dhabi
1000
11/0.433
09.05.2006
35.
ADWEA, Abu Dhabi
1500
11/0.433
19
30.05.2006
36.
ADWEA, Abu Dhabi
1000
11/0.433
30.05.2006
37.
ADWEA, Abu Dhabi
1000
11/0.433
12.06.2006
38.
ADWEA, Abu Dhabi
1500
11/0.433
12.06.2006
39.
ADWEA, Abu Dhabi
1000
11/0.433
11.07.2006
40.
Lindenberg Emirates, Abu

Dhabi
500
11/0.433
08.04.2007
41.
Al Hamad, Abu Dhabi
1500
11/0.433
11.07.2007
42.
ADWEA, Abu Dhabi
500
11/0.433
10
20.08.2007

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
500
11/0.433
29.08.2007
1500
11/0.433
27.10.2007
43.
ADWEA, Abu Dhabi
44.
Afaq Al Khaleej, Abu Dhabi
45.
ADWEA, Abu Dhabi
500
11/0.433
13
11.11.2007
46.
ADWEA, Abu Dhabi
500
11/0.433
10.04.2008
47.
Gulf Lights, Qatar
1600
11/0.433
12
24.03.2008
48.
Gulf Lights, Qatar
1600
11/0.433
29.03.2008
49.
GAMCO, Abu Dhabi
1500
11/0.433
03.04.2008
50.
Gulf Lights, Qatar

Qatar
1600
11/0.433
14.04.2008
51.
Gulf Lights, Qatar
1000
11/0.433
14.04.2008
52.
Gulf Lights, Qatar
1600
11/0.433
22.04.2008
53.
Gulf Lights, Qatar
1600
11/0.433
28.04.2008
54.
Gulf Lights, Qatar
1600
11/0.433
28.04.2008

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
55.
Gulf Lights, Qatar
1600
11/0.433
28.04.2008
56.
Gulf Lights, Qatar
1000
11/0.433
22.05.2008
57.
Gulf Lights, Qatar
1600
11/0.433
22.05.2008
58.
Gulf Lights, Qatar
1600
11/0.433
22.05.2008
59.
Gulf Lights, Qatar

Qatar
1600
11/0.433
31.05.2008
60.
Gulf Lights, Qatar
1600
11/0.433
31.05.2008
61.
Gulf Lights, Qatar
1600
11/0.433
31.05.2008
62.
Gulf Lights, Qatar
1600
11/0.433
26.06.2008
63.

Dhabi
500
11/0.415
31.07.2008
65.
Gulf Lights, Qatar
1600
11/0.433
28.08.2008
66.
Gulf Lights, Qatar
1000
11/0.433
28.08.2008
67.
Gulf Lights, Qatar
1600
11/0.433
28.08.2008

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
68.
Gulf Lights, Qatar
1600
11/0.433
08.10.2008
69.
Gulf Lights, Qatar
1000
11/0.433
08.10.2008
70.
Gulf Lights, Qatar
1000
11/0.433
08.10.2008
71.
Gulf Lights, Qatar
1600
11/0.433
13
13.10.2008
72.
Gulf Lights, Qatar
1600
11/0.433
13.10.2008
73.
Catic, Abu Dhabi
1500
11/0.415
27.10.2008
74.
Gulf Lights, Qatar
1000
11/0.433
28.10.2008
75.
Gulf Lights, Qatar
1600
11/0.433
28.10.2008
76.
Gulf Lights, Qatar
1000
11/0.433
28.10.2008
77.
Gulf Lights, Qatar
1600
11/0.433
12.01.2009
78.
Gulf Lights, Qatar
1000
11/0.433
12.01.2009
79.
Gulf Lights, Qatar
1000
11/0.433
12.01.2009
80.
Gulf Lights, Qatar
1600
11/0.433
10
22.01.2009

Sl.N
o.
Customer
KVA Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
81.
Gulf Lights, Qatar
1000
11/0.433
22.1.2009
82.
Seidco General Contg.,

Abu Dhabi
1500
11/0.433
28.02.2009
83.
Gulf Lights, Qatar
1600
11/0.433
22.03.2009
84.
Gulf Lights, Qatar
1600
11/0.433
14
08.04.2009
85.
Gulf Lights, Qatar
1600
11/0.433
30.04.2009
86.
ADDC, Abu Dhabi
1500
11/0.433
10
07.05.2009
87.
ADDC, Abu Dhab
1500
11/0.433
19.05.2009
88.
ADDC, Abu Dhabi
1000
11/0.433
19.05.2009
89.
Al Jizzi, Oman
1000
11/0.433
01.06.2009
90.
ADDC, Abu Dhabi
1500
11/0.433
10
30.06.2009
91.
ADDC, Abu Dhabi
1000
11/0.433
10
13.07.2009
92.
ADDC, Abu Dhabi
1500
11/0.433
10
26.07.2009

Sl.No
.
Customer
KVA
Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
93.
Gulf Lights, Qatar
1600
11/0.433
06.08.2009
94.
Gulf Lights, Qatar
1600
110.433
06.08.2009
95.
Gulf Lights, Qatar
1600
11/0.433
16.08.2009
96.
Gulf Lights, Qatar
1600
11/0.433
16.08.2009
97.
ADDC, Abu Dhabi
1500
11/0.433
49
23.08.2009
98.
ADDC, Abu Dhabi
1000
11/0.433
16
23.08.2009
99.

Dhabi
500
11/0.415
07.09.2009
100.
Gulf Lights, Qatar
1600
11/0.433
09.09.2009
101.
Al Jaber Est., Abu Dhabi
1500
3.3/0.415
31.10.2009
102.
1500
0.415/3.3
31.10.2009
103.
2000
11/3.3
31.10.2009
104.
Gulf Lights, Qatar
1600
11/0.433
Under Execution

Sl.No
.
Customer
KVA
Rating
Voltage Ratio
(kV)
Qty.
Date of Supply
105.
Gulf Lights, Qatar
300
0.415/3.3
Under Execution
106.
Gulf Lights, Qatar
1600
110.433
Under Execution
107.
Gulf Lights, Qatar
1600
110.433
Under Execution

International Recognition for Federal Transformers
Co. L.L.C Manufactured Dry Type Transformers
Sl.No.
Customer
KVA Rating
Voltage Ratio
(kV)
Testing Laboratory
1.
ADDC, Abu Dhabi
1500
11/0.415
KEMA - Netherlands
2.
ADDC, Abu Dhabi
500
11/0.433
KEMA - Netherlands
3.
ADDC, Abu Dhabi
1500
11/0.415
CESI Italy
4.
ADDC, Abu Dhabi
1000
11/0.415
CESI - Italy

Cast Resin Transformer

Uploaded by

Copyright:

Available Formats

Cast Resin Transformer

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cast Resin Transformer

Uploaded by

Copyright:

Available Formats

federal transformers Co. L.L.

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

Epoxy Resin Bisphenol based

The reaction of the epoxy resin with the hardener

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

federal transformers Co. L.L.C

Drake & Scull, Abu Dhabi

Gulf Contractors, Abu

Drake & Scull, Abu Dhabi

Drake & Scull, Abu Dhabi

Aster, Abu Dhabi

Petron, Abu Dhabi

Mapco, Abu Dhabi

federal transformers Co. L.L.C

Mapco, Abu Dhabi

Aster, Abu Dhabi

Thermo, Abu Dhabi

Aster, Abu Dhabi

Group 3, Abu Dhabi

Al Sabbah, Abu Dhab

Al Meraikhi, Abu Dhabi

Gulf Lights, Qatar

ETA Power Projects, Abu

federal transformers Co. L.L.C

Gulf Lights, Qatar

ABB, Abu Dhabi

Gulf Lights, Qatar

Hyundai, Abu Dhabi

Arabian Construction, Abu

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

federal transformers Co. L.L.C

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

ADWEA, Abu Dhabi

Lindenberg Emirates, Abu

Al Hamad, Abu Dhabi

ADWEA, Abu Dhabi

federal transformers Co. L.L.C