Electrical Performance
Glass fiber resin pouring structure can achieve the same power frequency and impulse level as oil-immersed transformers, and some design structures have impulse levels exceeding 200kV.
The cast type transformer has already withstood the test voltage (HV to HV, HV to LV to ground) and operating voltage in the atmospheric environment. Wire winding inter-turn and inter-layer only have a tiny differential pressure, are absorbed by the resin itself, and reached a very safe level. The inter-layer voltage of the foil winding is only the minimum voltage of each turn, the end of the winding has no helical angle, the magnetic leakage area is small, and the axial short-circuit resistance is strong. As the air-based insulation, this part of the insulation system will not deteriorate, will not age.
The wire winding adopts vacuum casting to obtain a uniform insulation structure, eliminates bubbles and voids, and avoids partial discharge in the winding. The inter-layer voltage of the foil winding is low and no partial discharge.
According to the IEC60076 standard, partial discharge tests shall be carried out on fully assembled transformers. In order to confirm the high quality of the design and production, the partial discharge test of each HV winding is carried out before the assembly.
In this way, the insulation in the HV winding can be checked to meet the quality requirements. The partial discharge termination voltage is at least 1.2 times than the rated voltage, and in most cases, even 2 times than the rated voltage. It is proved by this test that the winding is qualified.
Mechanical Properties
Glass fiber reinforced winding will not crack due to sudden fluctuations in temperature or thermal impulse.
Wire winding has been heated to the rated temperature, and then placed in ice water to cool for temperature change resistance test. All winding can pass such destructive tests.
Due to insulation and copper foil adhesive curing as a whole throughout the winding and the Foil winding is not cracking due to temperature fluctuations or sudden thermal shock.
Thermal Short Circuit Strength
According to Table III of the IEC 60076-5 standard, the maximum allowable average temperature of conductors after a short circuit for B, F, and H-class insulated copper wires is 350°C. For F-class copper winding transformers, the time “t” is determined, and after this duration, the final temperature will be:
T1 = T0 + a.Sk2.10–3[℃]
Among this:
- T0 – Initial temperature, ℃
- Sk – Short-circuit current density, A/mm2;
- t – Duration, S;
- a – A function of 1/2 (T1 + T0) (as shown in Table Ⅲ);
- T1 – Maximum allowable average winding temperature after short-circuit, ℃.
The following is calculated by the upper figure:
As all protection devices can cut off the transformer power within 10 seconds, the margin shown in this example is very large.
When the transformer is short-circuited, the conductor is heated rapidly in a matter of seconds. The resin around it is better than the conductor, can only be slowly heated, the conductor and resin surface temperature gradient will be great, and the greater the thickness of resin wrapped, and its gradient is too large. Even when the expansion coefficient is well matched, the mechanical strength of the winding must be taken into account, but the elastic glass fiber resin structure can be used to prevent cracking under the above conditions.
Moisture-resistance
The wire wound products are very well protected against moisture due to the copper conductor complete encapsulation in resin insulation. The transformer can be networked after long-term storage, and can be input into the power grid no-load.
The foil winding shall be stored in damp proof, and when the insulation resistance is lowered, it should be heated and dried before it can be put into use. When using, only compressed air can be used to remove sediment or dust.
Environmental Protection
The main concern of resin casting dry-type transformer is environmental protection. This question is actually a justification for the development of a cast type transformer:
A. Fire-resistance
The main feature of the resin casting transformer is flame retardant and self-extinguishing. Tests have shown that once a fault occurs inside the transformer and the protection device cuts off the transformer within the specified time, the winding itself will self-extinguish, thereby stopping the fire. If the external environment catches fire and all equipment and buildings are on fire, the epoxy resin may also burn, but the burning of the resin will not promote the spread of the fire.
B. Toxicity
The toxic components of combustion products are a major concern. Simulated tests were conducted in laboratories. Depending on the conditions and analysis methods, the results vary. According to OSHA requirements, if toxic substances are present, their concentrations are very low, allowing for prolonged exposure without harm.
C. Noise
In the wire wound transformer, the winding is not mechanically connected with the core, but the support structure is used to prevent the core ferromagnetic vibration from transmitting to the winding.
The winding and the core are supported by special materials in the foil winding transformer structure, which effectively reduces the ferromagnetic vibration and reduces the superposition of noise.
The outer surface of the core is covered with elastic resin, which can prevent further noise transmission, and its noise level is better than the national standard.
D. Pollution
Wire wound and foil wound transformers are completely dry structures with no liquid or gas insulation, so there is no leakage. There is no need to take additional measures to prevent leakage, so there is no pollution to the environment.