Transformers

AL-AHLEIA SWITCHGEAR CO.

K.S.C.C.
Kuwait
3
CONTENTS
I PRODUCT RANGE & STANDARDS 4
II TRANSFORMER MANUFACTURING 5
III WEIGHTS & DIMENSIONS 14
IV TRANSFORMER DATA 18
V TYPICAL FITTINGS 20
VI TESTING 21
VII SAFETY 22
VIII ERECTION OF TRANSFORMERS 22
IX QUALITY & EXTERNAL CERTIFICATIONS 22
Driven by a vision to pioneer, ASC has risen
from its humble beginning more than 25
years ago of a sole factory for LV boards,
to an organisation boasting of 11 factories
managing LV & HV Switchgear, Transformers
and Package Sub-stations, establishing itself as
the largest power equipment manufacturer in
the region.
ASC takes pride for being the leading local
manufacturer of HV products, transformers and
package S/S. Over time, ASC products have
attained a reputation for quality, reliability as
well as sustainability which gained recognition
in the industrial sector in the Middle East.
All products have been developed inside
the walls of the factory and will continue to
improve, because progress stops once the spirit
of pioneering is lost.
ion to pioneer, ASC has risen on to pioneer, ASC has risen
le beginning more than 25 e beginning mo
sole factory for LV boards, sole factory for
ion boasting of 11 factories on boasting of 11 factorie
HV Switchgear, Transformers HV Switchgear, Transformer
b-stations, establishing itself as -stations, establishing itself a
er equipment manufacturer in r equipment manufacturer i
e for being the leading local for being the leadi
HV products, transformers and HV products, t
ver time, ASC products have er time ASC produ
ation for quality, reliability as tion fo quality reliability a
bility which gained recognition ility which gained recognitio
sector in the Middle East. sector in the Middle East.
have been developed inside ave been developed insid
factory and will continue to factory and will continue to
e progress stops once the spirit e progress stops once the spiri
lost. ost.
4 5
II. TRANSFORMER MANUFACTURING I. PRODUCT RANGE & STANDARDS

A) PRODUCT RANGE
Oil Filled Transformers up to 50MvA & 132Kv
Cast Pesin Transformers up to 10MvA & 36Kv
"AI-AhIeia" design and manufacture the following types of transformers:
POWEP TPANSFOPMEPS
DlSTPlBUTlON TPANSFOPMEPS (Single & Dual Patio)
TPANSFOPMEPS FOP PETPOLEUM PEFlNEPlES FOP HAZAPDOUS
APEA/ZONES AS SPEClFlED BY CUSTOMEP
HEPMETlCALLY SEALED TPANSFOPMEPS
EAPTHlNG TPANSFOPMEPS
PEGULATlNG TPANSFOPMEPS
AUTO TPANSFOPMEPS
CONvEPTEP TPANSFOPMEPS
FUPNACE TPANSFOPMEPS (lnduction & Arc)

B) STANDARDS
{a) OiI FiIIed Transformers: "AI-AhIeia" make transformers conform to lEC / BSEN 60076
standards. However, "AI-AhIeia" provide transformers conforming to other standards as
per requirement of customers.
{b) Cast Resin Transformers: "AI-AhIeia" make transformers conform to lEC / BSEN 60076,
Part:11. However, "AI-AhIeia" provide transformers conforming to other standards as per
requirement of customer.
LAMlNATlON STACKlNG MACHlNE LAMlNATlON STACKS
LAMlNATlON CUTTlNG MACHlNE
LAMINATION CUTTING
6 7
WlPE WlNDlNG MACHlNE
FOlL WlNDlNG MACHlNE
WINDING MACHINES
vACUUM OvEN CHAMBEP vACUUM CASTlNG PLANT
DEDICATED PLANTS
FOlL WlNDlNG MACHlNE
WlPE WlNDlNG MACHlNE
ASSEMBLY LAMlNATlON (CAST PESlN) COPE & COlL FULLY ASSEMBLED
MOvlNG lNTO DPYlNG OvEN (OlL)
LAMINATION ASSEMBLY
Hv COlLS FOP DlSTPlBUTlON
TPANSFOPMEPS
Lv COlLS FOP DlSTPlBUTlON
TPANSFOPMEPS
COILS {OiI)
Hv SlDE vlEW FOP 1000KvA, 11/0.433Kv, OlL FlLLED TPANSFOPMEP vlEW FOP 1000KvA 11/0 433Kv OlL FlLLED TPANSFO TPANSFO
8 9
Lv COlLS
COILS {CAST RESIN)
COMPLETE COPE COlL ASSEMBLY
WlTH CONNECTlONS
Hv COlLS
TANK FABPlCATlON OF 30MvA TPANSFOPMEP
FABRICATION OF TANK & ROBOT WELDING
FABPlCATlON OF METAL PAPTS OF
TPANSFOPMEP
vAPlOUS TYPES OF CASTlNG
3D VIEW OF LAMINATION & COIL ASSEMBLY
20 MVA, 33/11.5 KV TRANSFORMER
CORE END STUDS LV BUSHING
LV CONNECTION BUSBAR
YOKE STUDS
HV BUSHING
LAMINATION
FLITCH PLATE
PRESSURE SCREW
ASSEMBLY
COIL PRESSING RING
HV TAPPING WINDING
HV MAIN LEADS
HV TAPPING LEADS
LEAD SUPPORT CLEATS
10 11
3D VIEW OF 30 MVA
132/11.5 KV, TRANSFORMER
SECTIONAL VIEW OF LAMINATION & COIL ASSEMBLY
30 MVA , 132/11.5 KV TRANSFORMER
12 13
14 15
III. WEIGHTS & DIMENSIONS
OIL FILLED TRANSFORMERS
Rating Ratio
Vector
Group
Reference
Length
{mm)
Width
{mm)
Height
{mm)
TotaI
Weight
{Kg)
TotaI
OiI
Weight
{Kg)
AA) Pad mounted, with conservator and breather
1000KvA 11/0.433Kv Dyn11 2050 1470 2000 3450 696
1250KvA 11/0.433Kv Dyn11 2080 1660 2360 4000 830
1600KvA 11/0.433Kv Dyn11 2190 1850 2430 4800 950
7500KvA 11/6.6Kv Dyn11 3395 3200 3800 14595 3025
BB) Hermetically sealed with welded cover
1000KVA 6.6/0.46KV Dyn11 2300 1850 1745 3570 714
1500KVA 11/0.460KV Dyn11 2400 1920 2000 5020 1045
2000KVA 3.45/0.460KV Dyn11 2750 2550 2050 6065 1255
CC) Pad mounted, hermeticaIIy seaIed with boIted cover
400KvA 11/0.4Kv Dyn11 1790 1163 1413 2050 435
630KvA 11/0.4Kv Dyn11 1830 1340 1613 2650 565
1000KvA 11/0.4Kv Dy n11 1830 1612 1633 3275 610
2000KvA 6.6/0.4Kv Dyn11 2430 2195 2085 5650 1070
2000KvA 11/0.4Kv Dyn11 2430 2195 2085 5650 1100
12.5MvA 11/3.45Kv Dyn11 4550 3150 4400 21650 4750
DD) 33kV CIass oiI hIIed, power transformers
7500KvA 33/6.6Kv Dyn11 3700 3275 3750 16528 3633
7500KvA 33/11Kv Dyn11 3700 3275 3750 16240 3633
10MvA 33/6.6Kv Dyn11 4010 3450 4170 19480 4060
20MvA 33/11.5Kv Dyn11 5700 4000 4300 48000 11600
25MvA 33/6.6Kv Dyn11 5600 4050 4770 35974 6845
EE) 132kV Class oil lled, power transformer
20/30MVA 132/11.5KV Dyn11 6725 5450 5550 77000 26000
Weight and dimension of transformers other then the above will be provided on demand.
CAST RESIN TRANSFORMERS
Weight and dimensions of cast resin pad mounted transformer of ratings 250KVA,
1000KVA, 1250KVA & 1600KVA, AN cooIed.
Rating Ratio
Vector
Group
Reference
Length
{mm)
Width
{mm)
Height
{mm)
TotaI Weight
{Kg)
250KvA 11/0.433Kv Dyn11 1860 1550 1550 1600
750KvA 11/0.433Kv Dyn11 2300 1770 2300 3900
1000KvA 11/0.433Kv Dyn11 2300 1770 2300 3900
1250KvA 11/0.433Kv Dyn11 2300 1770 2430 4680
1600KvA 11/0.433Kv Dyn11 2450 1900 2590 5855
Weight and dimension of transformers above 1600KvA rating will be provided on
demand.
CAST RESIN TRANSFORMER
TYPE ATC12
16 17
11/0.433 kV TRANSFORMER
TYPE ATO12
11/0.433 KV TRANSFORMER
TYPE ATO12
COPE COlL ASSEMBLY OF
30MvA POWEP TPANSFOPMEPS
30MvA TANK
30MvA POWEP TPANSFOPMEP
UNDEP TANKlNG
30MVA POWER TRANSFORMER
19 18
IV. TRANSFORMER DATA
DESIGN FEATURES
Transformer designs are developed using CAD (Computer Aided Design), which in turn, are well
connected to CNC and other most modern machines to manufacture the right component.
STEPS IN MANUFACTURING OIL FILLED TRANSFORMERS
Core Construction
The core is constructed from lamination of Cold Polled Grain Oriented, Electrical Sheet, featuring
excellent magnetic properties. lt is cut on most modern CNC core cutting machines for step-lap
construction.
Windings
Al-Ahleia make oil flled transformer windings for distribution transformers uses Copper foil for
Lv winding and paper insulated rectangular/round wire for Hv winding. Sometimes enamelled
conductors are also used. State-of-the-art layer winding machines for winding Hv coils are
used maintaining accuracy of dimensions. For power transformer windings, Lv coils are made
either spiral or helical type. Specialized disc windings and inter-leaved disc windings will be used
having very high series of capacitance giving a very good lmpulse voltage performance.
Core & CoiI AssembIy
Core & Coil assembly for distribution transformers uses special insulating material like crepe
paper tube and are very strong and robust in construction to withstand short-circuit forces. They
are adequately clamped with the tank so that no movement is possible within the tank because
of transport jerks or short-circuit forces.
Fabrication
Transformer tanks are manufactured in the most modern plant having facility of automatic
component manufacturing using CNC machines which reads the component drawing directly
issued by Design department. Welding is done by welding robot ensuring very consistent and
leak proof welds. Tanks are leak tested after fabrication and shot blasted in our shot blasting
plant. After shot blasting and thorough cleaning, they are powder coated in our powder coating
plant, or if required, painted in our liquid paint plant, as the case may be. Al-Ahleia can produce
transformer tanks of the required ratings in their production range.
Vacuum/Vapour Phase Drying Process & Tanking
The core and coil assembly is dried in an oven to improve insulation resistance and remove
ingress of moisture in the insulation materials.
The dried core coil assembly is boxed up in a pre-fabricated M.S. Tank, and vacuum/vapour
phase process is applied for flling oil in the transformer tanks.
Testing
All Poutine/Type tests as per the relevant standard / customer specifcations are conducted.
Every oil transformer is pressure tested, and then fnished, including all fttings and kept ready
for despatch.
STEPS IN MANUFACTURING CAST RESIN TRANSFORMERS
Core Construction
The core is constructed from lamination of Cold Polled Grain Oriented, Electrical Sheet, featuring
excellent magnetic properties. lt is cut on most modern CNC core cutting machines for step-lap
construction.
Windings
Al-Ahleia cast resin transformers are wound with Lv foil winding and Hv sectionalized coil winding.
There is a uniform distribution of ampere turns, throughout the length, resulting in very less
short-circuit axial forces. State-of-the-art winding machines enable insulation and conductor
materials to be wound simultaneously, resulting in a very good compact winding, capable of
resisting short circuit forces. Hv coils are made from suitably insulated copper conductors.
Core & CoiI AssembIy
Core and Coil assembly for cast resin transformers uses Class `F` insulation for 155C. The clamp
plates and the clamping frames are insulated with core using fbre glass sheets. Anti-vibration
pads are provided at the feet to isolate any vibration from the transformers to be transmitted to
the enclosure. High strength coil support blocks are used to keep the resin cast coils in position
on the core.
The core is painted with epoxy resin so that atmospheric pollution will not affect the core steel
surface. Also, it will have dampening effect on the noise produced if any.
EncIosures
Enclosures are generally manufactured from zinc coated steel sheet. The standard fnish is
a polyester based powder coat. The protection categories as per relevant lP number can be
provided based on customer requirement. Enclosures are made on most modern computerized
metal sheet working machines.
Casting
Cast resin transformer coils, both Hv and Lv, are casted with epoxy resin, in the most modern
fully automatic casting plant. The casting plant is state of the art one having thin flm degassing
mixers. The resin mixtures are prepared by automatic weighing and loading of epoxy, resin and
fller components and thereafter loading them into the mixers before casting. Pre-heating of the
coils is done after casting while post-curing is done in the post curing ovens resulting in void free
coils.
Testing
All Poutine/Type tests as per the relevant standard / customer specifcations are conducted.
20 21
V. TYPICAL FITTINGS
BUSHINGS HV & LV:
Bushings/Monoblock is used to take out Hv/Lv terminals out of the transformer for terminations.
voltage/Current Pating is selected according to the system voltage requirement.
GASKETS:
Gaskets are used in transformers for oil sealing. They are made of rubber bonded cork as per
requitements.
AH-CISD - Common lntegrated Safety Device
Al-Ahleia make AH-ClSD is used for transformer protection by detecting oil level,
discharge of gas, tank pressure, and temperature.
HlGH vOLTAGE TEST SET 500Kv AND lMPULSE TEST UP TO 1000 KvA
VI. TESTING
Following test facilities are available at Al-Ahleia works
for transformers up to 50MvA, 132Kv class. Tests are as per lEC-60076.
ROUTINE TESTS
(1) Measurement of Winding Pesistance
(2) Measurement of voltage Patio and Check of Phase Displacement
(3) Dielectric Test
(a) Power Frequency Separate Source High voltage Test
(b) lnduced Over voltage Test
(4) No Load Loss and Exciting Current
(5) Load Loss and lmpedance voltage
(6) Partial Discharge Test - For 132Kv Oil Type Transformers & 11Kv Cast Pesin Transformers
22 23
VII. SAFETY
1. Pead and understand the entire instruction bulletin supplied along with the transformer before
installing, operating or maintaining "AI-AhIeia" transformers. Follow all applicable local and
national codes.
2. Many parts of the transformer operate at high voltages. DO NOT TOUCH. Use only
electrically insulated tools and clothing, and protective gear when working around electrical
equipment.
3. Do not rely on visual indications such as switch position or fuse removal for determining a
de-energized condition. Always assume that a terminal is energized unless it is checked with
a properly rated meter to ensure the terminal is de-energized and grounded.
4. After doing the electrical tests, and before touching the transformer, ensure all static charge
has been discharged by grounding the coils with an appropriate grounding device.
5. This equipment must be installed and serviced only by qualifed electrical personnel.
6. Turn off all power supplying this equipment before working on or inside the equipment.
7. Always use a properly rated voltage sensing device to confrm power is OFF.
8. Peplace all devices, covers etc., before turning on power to this equipment.
FAILURE TO FOLLOW ANY OF THESE PRECAUTIONS WILL RESULT IN DEATH OR SERIOUS
INJURY.
VIII. ERECTION OF TRANSFORMERS
"AI-AhIeia" is in the feld of lnstallation and maintenance of electrical equipments for the past two
decades.
Dedicated and specialized team for lnstallation, Commissioning, Maintenance and after Sale
support for all type of Transformers is available.
IX. QUALITY & EXTERNAL CERTIFICATIONS
"AI-AhIeia" quality assurance system conforms to lSO 9001:2008, 29001:2007, 14001:2004
systems certifed by DNv.
"AI-AhIeia" transformers are tested as per latest lEC and customer specifcations.
SOME OF OUR VALUED CLIENTS
Government Sector OiI Sector Companies
Ministry Of Electricity & Water
Ministry of Defense
Ministry of Health
Ministry of lnformation
Ministry of Public Work
Kuwait Oil Company
Kuwait National Petroleum Company
Petrochemical lndustries
Kuwait Aviation Fuelling Company
KGOC (JO Wafra / JO Khafji)
Chevron
PubIic Sector PMC
Kuwait Port Authority
Director General of Civil Aviation
Public Authority of Housing Welfare
Kuwait University
Fluor
Amec
Worley Parsons
EPC Contractors
Hyundai Heavy lndustries
Hyundai Engineering & Contracting Co.
Daelim
SK Engineering & Contracting Co.
Snamprogetti / Saipem SpA.
National Contracting Co.
Petrofac
Tecnicas Peunidas S.A - Group TP
Technip
Mitsubishi
Ganz
Areva
Siemens
ABB
Ansaldo
Export {PubIic & Private)
South Oil Company (Basrah, lraq)
Qatar General Electricity & Water Corporation
Kahramaa , Qatar
EDD - Bahrain
UNEECO - Bahrain
lTTC, Qatar
voltage Engineering Ltd., Qatar
Al-Bakali General Trading Co., Bahrain
Omar Zawawi Establishment, Oman
Private Sector
Heavy Engineering lndustries &
Shipbuilding Company (HElSCO)
Kharaf National
lntegral Services Company W.L.L. (lSCO)
Mishrif lnternational For Trading &
Contracting Co.
lnstruments lnstallation & Maintenance Co.
(lMCO)
Almeer Technical Services Company
Combined Group Co. For Contracting
K.S.C.C.
Maschinenfabrik Peinhausen (MP)
JAN 2010 9089 / 06
Copy Rights 2010 - AI-AhIeia Switchgear Co.
AII Rights Reserved
GPS Location
29 13' 59.40" N - 48 00' 59.76" E