Training Report Casting of Transformers

By

Khushal H Sukhadia

Under The Guidance Of

Mr. Satya Shravan

Casting 2012

Index
Topic 1. Objective 2. Introduction 3. Casting Techniques 3.1 Vacuum Pressure Impregnation 3.1.1 Materials Used 3.1.2 Measurements 3.1.3 Process 3.2 Cast Resin 3.2.1 Materials Used 3.2.2 Pre Casting Process 3.2.3 Casting Process 4. Quality of Casting 5. Conclusion Page 3 3 3

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1. Objective
To learn the process of casting, its importance and the quality aspects of casting, the unique casting process of Raychem RPG and factors that make it a market leader in dry type transformer

2. Introduction
Casting of the dry type transformer is the most important aspect. The performance of the dry type transformer depends mainly on the casting process. It is the mastery in this process that has earned Raychem RPG a specialist in making different types of dry type transformers, even at higher ratings and special transformers. It is a very critical, and hence difficult, process because if there is any error during the casting process, it is very difficult to recover. This process increases insulation and mechanical strength of winding. Dry type transformers are used in different environments mainly indoors as there are very few hazards.

3. Casting Techniques
Dry type transformers are classified on the casting techniques used. There are two types of techniques. They are as follows.

3.1

VPI (Vacuum Pressure Impregnation)

In this technique, after treatment in oven to remove the moisture in the insulation, the coils are made to undergo treatment with certain polymers in the impregnation tank. The VPI process includes applying varnish over the coil under vacuum, and hence the name VPI. This process allows better penetration of varnish in the coils of the transformer. These units offer an increased insulation level at a reasonable cost. It has a very long life and is almost free of maintenance. Also, in this technique particularly, there is a possibility of rework in the windings if any error is detected.

3.1.1 Materials Used

i. ii. iii. Dobeckan FT 2005/500 EK Polysteramide base resin. Diluent V Inhibitor UP1

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Figure 1: Vacuum Impregnation Unit

3.1.2 Measurements
i. Check the viscosity of the resin at of temperature of 23 0C. It must be within 100 - 150 seconds. If it is more than 150 seconds, add diluent V. When diluent V is added in the resin in the storage tank, stir the resin for 2 and a half to 3 hours and then take the sample to check the viscosity. The following method should be adhered to for sampling of resin for checking viscosity. a. Start the stirrer 30 minutes before taking the sample. b. Temperature of the resin in the storage tank should be 23 0C. c. Drain out the initial 500 to 750 ml (approximately) resin from the sampling pipe/ storage tank and then take the resin sample. d. Check the viscosity of resin sample. ii. iii. iv. Vacuum level achieved in chamber should be less than 1mbar. Check the pressure during pressurization 3.5-4 bar. Temperature of coil while loading into chamber should be 450 C +/- 50 C.

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3.1.3 Process
a) Preheat the transformer coil for a minimum of 4 hours at temperature of coil at 115 C 5 C. b) Cool down the coil to 55C 5C. c) Load the coil of 55C 5C temperature in the vacuum-impregnating chamber at 55C 5C. d) Apply a vacuum of 3 to 5 mbar and continue the vacuum cycle for 60 minutes and switch off vacuum pump. Ensure storage tank temp temperature attains 40 C 5 C before the start of flooding. e) Flood the resin in the impregnation chamber. Allow the resin to slowly fill up to 20 mm (approximately) above the height of the coil. f) Keep the coil under the resin for 30 minutes under vacuum in submerged condition. g) Break the vacuum with dry air and apply a pressure of 3.75 0.25 kg/cm2 with dry air. Maintain the pressure for 30 minutes. h) Reduce the pressure to 0.5kg/cm2 and transfer the resin/varnish back to the storage tank and cool the resin to less than 27C. i) Keep the coil for a minimum of 30 minutes inside the chamber for dripping in angled position. j) Transfer the coil to a preheated oven preset at 158 C and cure the coil for 12 hours after the coil temperature reaches 160 5 C. k) Cool the coil to room temperature and proceed for further assembly work.

3.2

Cast Resin
This process incorporates encapsulation of the coils in epoxy by a molding process. The transformer coils are solidly cast in resin under a vacuum in a mold. The manufacturing process locks the winding in a strong epoxy resin with high dielectric strength protecting the transformer from severe operating environments and improved abilities to withstand heavy electrical surges such as short duration overloads experienced by transformers serving industrial processes.

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Casting 2012

Figure 2: Autoclave

CRTs are relatively new. Care must be taken to ensure that the set procedure is followed strictly as an error at this stage makes the entire winding worthless. This incurs huge losses. Cast resin is generally preferred when transformer needs: 1. Additional strength and protection are required. 2. Good outdoor installation. 3. Protection from harsh environment (chemical, salts, dust, caustic gases, moisture, etc.)

3.2.1 Materials Used

i. ii. iii. iv. Resin Cy205 (Epoxy) Hardener Hy905 Plasticizer Dy040 Accelerator Dy060 Page 6

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v. vi. vii. Filler (Quartz silica M10) Coloring paste Paint (Epoxy)

Silica powder is used as filler in CRT. The function of filler is to increase the density of resin. As silica is an insulating material, the insulation resistance of CRT is high. Addition of plastisizer to the resin increases the plasticity of material. The function of accelerator is to accelerate the process of chemical bonding between resin and hardener.

Figure 3: Control Panel for the Autoclave

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3.2.2 Pre Casting Process
After finishing the winding following steps are taken before the coil is put in the autoclave. Brazing of the tap is done & continuity check is performed. Resistance of the winding is checked to ensure it is within permissible limit. Coil is held in vertical position on the stand & outer shell suitable for the coil is fitted. Release agent QZ 13 is applied to the tapping plate so that it can be removed easily once the casting process is complete. Silastic 1080 sealant material is used to seal outer shell so that no resin will spill out during casting process.

3.2.3 Casting Process

a) Take the resin and hardener in their respective storage/degassing tanks. Set the temperature to 65 & 600C +/-10 respectively. b) Load the filler in the sack emptying station and set the temperature at 85 0 C +/- 5. c) Select the appropriate program from the list and mix the filler with resin and hardener in storage/degassing tanks. Switch on the vacuum after 10 minutes and ensure that it is maintained at 3 to 5mbar +/-0.5 for 1 hour. The temperature is maintained at 650C & 600C +/-5 respectively for complete degassing. d) Take the resin in resin mixer and start degassing, ensure the vacuum is less than 10mbar for 30 minutes and temperature is 550 C +/-5 e) Manually add the plasticizer and the coloring paste into the resin. The accelerator is added to the hardener as per the E-spec. They are mixed for 1 hour under a pressure of 3 & 5mbar +/-0.5 for 30 minutes at a temperature of 650C +/-5. f) Load the preheated mold coil assemblies (1100C +/- 5 for a minimum of 4 hours) into the preheated autoclave (800C +/- 5) g) Connect the filling pipes with nozzles. Switch on the vacuum and ensure that it is maintained at a pressure of 5mbar for 1 hour. h) Start filling, check the level through view glass. Fill the coils up to 20mm (approximately) above the winding. i) Release the vacuum through dry air by airing valve. j) Check for leakage, if any, and repeat the above 3 steps after arresting the leak by means of POP or equivalent material. Raychem RPG Pvt. Ltd., Chakan Page 8

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k) Apply pressure in autoclave (1.5kg/cm2) & maintain for 30 minutes. l) Shift the molded coil assemblies for semi-curing in preheated ovens (1100C +/- 5) for 9 hours. m) Clean the static mixer & nozzles with resin. n) De-mould the after semi-curing. o) Complete the post curing at 450C +/- 5 for 6 hours. p) Complete the sizing & finishing of coil. After this procedure, the coils are taken out and the nylon ducts are removed. The coils are ready for further assembly.

4. Quality of Casting
There are many things that may go wrong during the casting process. Air pockets, unfilled gaps, leaks, change in physical dimensions, unwanted and uncontrollable chemical reactions, impurities in the chemicals are just a few examples of the things that may hamper the quality of the casting. Hence, thorough inspection is needed. Apart from physical dimensions, the following parameters are checked. 1. Insulation resistance value should be equal to or greater than 20000 Mega Ohms. 2. Partial discharge should be less than 25 pc 3. Transformer must pass all routine tests with cast coil as processed above.

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5. Conclusion
The casting is the most essential part in the manufacturing of dry type transformers. The high insulation levels and good mechanical strength are maintained by strictly following the procedure for casting of CRT and VPI transformers. The process has been observed and its effects on the overall functioning of the transformer were well understood. Raychem RPG has state of the art casting techniques with imported machinery. The use of PLCs in the operation of the machines makes it highly accurate. The weight and pressure are set to the fed levels with high precision. Since the chemical reactions need its favorable environment, the above mentioned parameters are to be maintained at their precise levels. This can be done only by good machinery. This, along with high quality chemicals, is what makes Raychem RPG a specialist and a market leader in dry type transformer.

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