EL SEWEDY TRANSFORMERS

EGYPT
New Subsidiary by El Sewedy Cables

1
 Egypt Factory

In Elsewedys modern 10th Ramadan City premises,

built over an area of 57,887 m2, of which 37,627 m2 is
closed area, ELSEWEDY CABLES will produce Power
and Cast Resin Transformers and offers a complete
range of systems, components and services
ELSEWEDY CABLES will be the first manufacturer in
this sector in Egypt.
2
 ELSEWEDY
TRANSFORMERS

SUBSIDIARY OF ELSEWEDY CABLES

WHAT IS TRANSFORMER?
 ELSEWEDY
TRANSFORMERS

SUBSIDIARY OF ELSEWEDY CABLES

 ELSEWEDY
TRANSFORMERS

SUBSIDIARY OF ELSEWEDY CABLES

TRANSFORMER IS A SET USED TO

CHANGE THE VOLTAGE AND
CURRENT FROM SIDE TO OTHER SIDE
 ELSEWEDY
TRANSFORMERS

SUBSIDIARY OF ELSEWEDY CABLES

22KV 220KV
 Components of Electric Network

Step up transformer O.H.T.L. Step down transformer

G D.

Generation Transformation Transmission Transformation Distribution

Planned Manufacturing Program
Distribution Applications :
Distribution Transformers (100-3150 kVA)
Mono-phase Transformers
Earthing Transformers

Power Applications :
Power Transformers (4000 kVA up to 10 MVA)
Transformer with On Load Top Changer
Auto-transformers
Generator Transformers

Industrial Applications :

9
Rectifier Transformers with 3 or 4 windings (double storey)
 Cast Resin Transformers
Product in Details
1) Core
2) LV terminal
3) Resilient spacer
4) HV terminal
5) LV coil
LV aluminium foil winding insulated with Prepregs and hot-
polymerised resin
- Reduction of the axial and radial short-circuit forces to a minimum
- High resistance to short-circuits-
- Inclusion of cooling channels if required-
6) HV coil
HV winding copper or aluminium conductors cast under
vacuum into moulds reinforced ion materials.
7) Tapping link
8) Delta connection rods
9) Earthing
10) Yoke clamping and wheelbase
11) Roller

10
 Technologies

HV cast under vacuum HV cast under vacuum

LV cast under vacuum LV impregnated foil

HV copper HV copper
LV copper LV copper

HV aluminium HV aluminium
LV aluminium LV aluminium

HV Copper
LV aluminium

11
 Cont. Technologies

HV cast under vacuum

LV cast under vacuum This technique
allows upto
HV copper 20 MVA rated power
LV copper
&
HV aluminium
36 kV HV
LV aluminium
&
36 kV LV windings

12
 Cont. Technologies
HV cast under vacuum
This technique
LV impregnated foil
allows upto
3150 kVA HV copper
LV copper
rated power
& HV aluminium
LV aluminium
36 kV HV
& HV Copper
LV aluminium
1,1 kV LV windings

13
 Low Voltage

Foil winding =>

high mechanical
resistance to short-circuits

conductor material: aluminium

or copper foil
layer insulation: pre-impregnated
polyester film of insulation class F

First pre-impregnated film winding,

not yet hardened; then the hot-
polymerisation of the resin with the
polyester and conductor material
results in a rigid, temperature
resistant body. Insulation
Conductor Core
14
 High Voltage

Copper or Aluminum

H Class (185 C) Conductor insulation

Cast under vacuum

Free Partial Discharge

High Dielectric Strength against lightning impulse

15
 Core design

Standard range (normal and reduced losses):

Core sheets: - FeM-140-30-S (M5X), cold rolled, 0.27-0.3 mm

- grain oriented, low-loss
- Carlite-insulation

Interfaces: - Cutting angle of 45

- Step-Lap

Section: - round (Column and yokes)

protected by a protecting varnish

16
 TEST
Routine electrical tests:

Routine tests are carried out on all transformers at the end

of manufacturing and are subject to official test report.
These tests:

- Measurement of winding resistance

- Measurement of ratio and vector group
- Measurement of impedance voltage
- Measurement of load (copper) loss
- Measurement of no-load (iron) loss
- Measurement of partial discharge
- Applied voltage test
- Induced voltage test
17
 TEST
Type Tests
Lightning Impulse test
-Temperature rise test
Special Tests
- Noise level test
- Short-circuit test
- Environmental test for E2 Class for frequent
condensation or heavy
pollution or combination of both.
- Thermal shock test for C2 Class for operation,
transport and storage at
ambient temperatures down to -25 oC.
- Fire behavior test for F1 Class for subject to a fire
hazard.
18
 Environmental Classes

Environmental classes according to HD 464.S1:

E0 indoor installation only

E1 occasional condensation and limited pollution
E2 frequent condensation and/or heavy pollution

19
 Climatic Classes
Climatic classes according to HD 464.S1:

C1 indoor installation only; operation at ambient

temperature >- 5 ; transport and storage down to -25 C

C2 transport, storage and operation down to -25 C

Test procedure (new):

20
 Fire Behaviour Classes

Fire behaviour classes according to HD 464 S1:

F0: no special fire hazard is envisaged

F1: transformer is subject to fire hazard restricted

21
 Insulation Class and Temperature rise
Both High-voltage and Low-voltage windings of the Dry Type Transformers are
manufactured using insulating material class F (IEC 60076-11 permitted
average winding temperature rise of 100 K at a max. ambient temperature of
40C )

Different Classifications:

Average
Class of Max.
permitted
temperature
Insulation temperature
of the system
Materials rise for
(oC)
conductors (K)

B 80 130

F 100 155

H 125 180

22
 Overload Capability

- Dry Type Transformers can be overloaded up to 40% (with a

corresponding increase in impedance voltage)
With installed additional radial cooling fans

- Short-time overloads are uncritical as long as the maximum-

winding temperatures are not exceeded for extended periods of
time.

23
Accessories:

Temperature Monitoring (standard)

-Fitted with three temperature sensors

installed in the LV winding,

-Alarm and tripping device with relay output.

24
Accessories:

Cooling Fans (upon customer request)

-Installed on both sides of transformer

-The fans are automatically switched on and

off by means of additional sensor

25
Accessories:

Anti-Vibration Pad (upon customer request)

To insulate the transformer body against noise
transmission for installation in buildings and
shopping centre

26
Accessories:

Enclosures (upon customer request)

Indoor installation in electrical operating
rooms or in various sheet-metal enclosures
is the preferred method of installation.

- The transformers need only be protected

against access to the terminals or the
winding surfaces, against direct sunlight,
and against water.

27
Enclosures for Dry Type transformers are according to IEC
60529.
The general protection degrees in market:

Indoor:

IP20
IP21
IP23
IP31
IP33

Outdoor

IP23
IP33

28
 LV connection Temperature control
system

Rating plate

Assembly at site

HV coil

Core
Pressure plate
LV coil

HV connection Pressure plate insulation

Core bandage Yoke clamping

insulation
Resin spacer
Yoke clamping
Press part
Wheelbase
Wheel

29
Current Situation - Local Competition
 Some Photos from Factory

31
 Some Photos from Factory

32
 Some Photos from Factory

33
Cut To Length Machine

34
 Some Photos from Factory

35
Foil Winding Machine

36
Automatic Winding Machine

37
 Some Photos from Factory

38
 Casting Equipment

39
 Some Photos from Factory

40
 Some Photos from Factory

41
 Applications

This new factory is the first of its kind in MENA and can
produce several types of transformers which are
required for all types of projects (construction, Industry,
wind energy generation, infrastructureetc)
 Advantages

Hardly inflammable, self-extinguishing

No pollution of the environment.

Installation close to the centre of major consumers

Reduce cable costs, transmission losses, installation costs

No Maintenance is required

Free from all restrictions that apply for oil type transformers such as oil
collecting pits, fire walls etc.

Smaller Size

43
 Cont. Advantages

Highly moisture-proof. The transformer can operate under 100%

relative humidity and be switched on without pre-drying even after a
long period of storage.

Low partial discharge. Therefore high life expectancy.

Cooling is the most efficient. Forced cooling system increase of

permissible load up to 40%.

Excellent insulation level, short circuit and lightning strength.

It is able to handle greater short time overloads than oil filled

transformers. Because of the time constant.

44
 Cast Resin vs. Oil Transformers
No-load Losses Comparison (for 11 kV)

200 kVA 500 kVA 1000 kVA 1600 kVA

Dry Transformer (El Sewedy) 0.65 kW 1.2 kW 1.8 kW 2.5 kW

Oil Transformer (Elmaco) 0.51 kW 0.89kW 1.4 kW 2.17 kW

Oil Transformer (Siemens) 0.55 KW 1.1 KW 1.7 KW 2.6 KW

45
 Cast Resin vs. Oil Transformers
load Losses Comparison (for 11 kV)

200 kVA 500 kVA 1000 kVA 1600 kVA

Dry Transformer (El Sewedy) 2.3 kW 5 kW 8.5 kW 12.5 kW

Oil Transformer (Elmaco) 3.73 kW 7.9 kW 14.23 kW 20.25 kW

Oil Transformer (Siemens) 3.6 KW 7.1 KW 13 KW 20 KW

46
 Cast Resin vs. Oil Transformers
Noise Level Comparison (for 11 kV)

200 500 1000 1600

kVA kVA kVA kVA

Dry Transformer (El Sewedy) 47 dB 51 dB 55 dB 56 dB

Oil Transformer (Elmaco) 48 dB 52 dB 54 dB 56 dB

Oil Transformer (Siemens) 48 dB 53 dB 55 dB 57 dB

47
 Comparision Cast Resin Transformers vs.
Oil Transformers

Dimensions (for 11 kV)

200 kVA 500 kVA 1000 kVA 1600 Heigh
Lengt kVA
Length Height Length Height Length Height h t
Dry
Transformer 1125 1220 1305 1550 1590 1650 1800 1900
(Elsewedy) mm mm mm mm mm mm mm mm
Oil
Transformer 1190 1450 1500 1710 1790 2095 1970 2315
(Siemens) mm mm mm mm mm mm mm mm

48
 Mandatory Data to be Known
Rating
Voltage Ratio (HV / LV ) in KV
Winding Material (HV / LV)
Insulation Method ( HV / LV)
Cooling method
Enclosure Degree of protection
Insulation System ( Class )
Max. ambient temperature
Tapping range (on HV-Side)
Impedance%
Vector Group

49
 Mandatory Data to be Known

1 Project Name
2 Customer Name
3 Consultant Name
4 Tender Job in Hand or
5 Tender Date
6 .Specs
7 B.O.Q

50
 Precautions
1- Transformer Room Ventilation

51
 Precautions
2- Installation

2.1) Room must be dry and clean

2.2) Flowing of water must be prevented
2.3) Adequate ventilation must be provided
2.4) Distance from the wall must be respected
2.5) Spacing of the HV cables
2.6) Check all screws on HV coils & on LV connections
2.7) The connection cables for transformer auxiliary shall be fixed
rigidly to cable channels adequately
isolated from active parts as per the requirements of standards.

52
 Precautions

3. Start up

3.1) Check the transformer data given in the rating plate.

3.2) Control the earthing of the transformer on the upper frame.

3.3) Check the phase connections.

3.4) Bolts for the tappings and HV terminations have to be

checked to comply with torsional moment requirements.

53
 Precautions
3. Start up

3.5) The cleanness of the transformer can be checked by using

a 2500 V megger, to check insulation resistance of HV/earth,
LV/earth and HV/LV.

The approximate values of resistances are:

HV/Earth 250 M LV/Earth 50 M

HV/LV 250 M

3.6) All metal parts, cable remains or tools must be removed

prior to switching on the transformer.

54
 Precautions
3. Start up

3.7) Tap changing can be proceeded as below:

- The transformer is off-circuit.
- Move up the tapping link.
- Choose the appropriate position number for
the end work regulation refering to the rating plate.

- Mount the tapping link acc. to the position

plate, which is located right down the rating plate.
(Look for the max. torsional moment)

3.8) Check the function of temperature protection system.

55
 Precautions
4. Maintenance recommendation
4.1) In principle ESCART cast resin transformers are maintenance
free. Care must be taken so that cooling air is not prevented
from circulating around the transformers fitted with enclosure.

Once in a time, visual inspection (Please respect the electrically

safety distances), depending on the environmental conditions,
without disconnecting the transformer should be made.

Should maintenance be needed on customer wishes, please

proceed as follows:

4.2) Prior to starting maintenance work, the transformer should

be de-energized.
4.3) All terminations should be earthed and short-circuited.

56
 Precautions
4.4) Under normal working and environmental conditions
checking of firmness of terminations and tapping links and
cleaning of transformer with dry compressed air or nitrogen
once a year is necessary. The frequency of cleaning depends
on the pollution of environment.

4.5) Check the painting of iron parts, and if necessary touch up.

4.6) Check the torque moments for earthing, tap charging

screws and for HV-connections.
(Look for the max. Torsional moment)

4.7) Check the function of temperature protection system.

57
 Certification

58
 Questions & Answers

59
 Thank You

Prepared by:
Suleyman Demirkaya

60