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federal transformers Co. L.L.

C
DRY TYPE CAST RESIN TRANSFORMER

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN 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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

federal transformers Co. L.L.C


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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
6. Manufacturing Process
Winding
Mould Assembly
Preheating
Casting
Curing
Finishing & Testing of Coils

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

federal transformers Co. L.L.C


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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
12. Applications
High Rise Buildings
Air ports
Shopping Malls
Cinema Halls
Airports
Hospitals
Generating Stations
Factories etc.

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
Installed Annual Production Capacity 1,200 MVA
Ratings upto 5,000kVA 36kV Class

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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.

Drake & Scull, Abu Dhabi

2500/3300

11/3.3

15.10.2002

7.

Drake & Scull, Abu Dhabi

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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.

Lindenberg Emirates, Abu


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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
Supply Record of Federal Transformers Co. L.L.C
make Dry Type Cast Resin Transformers
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.

Lindenberg Emirates, Abu


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.

Al Jaber Est., Abu Dhabi

1500

0.415/3.3

31.10.2009

103.

Al Jaber Est., Abu Dhabi

2000

11/3.3

31.10.2009

104.

Gulf Lights, Qatar

1600

11/0.433

Under Execution

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
Supply Record of Federal Transformers Co. L.L.C
make Dry Type Cast Resin Transformers
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

federal transformers Co. L.L.C


DRY TYPE CAST RESIN TRANSFORMER
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

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