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Just like oil filled transformers , there are varieties of windings in cast
resin transformers too.
Winding technique
LV Foil winding:
It uses a single piece of thin strip as conductor. Width of the foil is equal to length
of the winding.
insulation. During curing process foil and insulation are bonded together to form a
rigid block. The LV coil becomes self supporting against forces.
Eddy losses in the thin foil are very less compared to thick rectangular wires,so
windings made with foil are cooler than other types.
Foil winding minimizes the axial forces during short circuit , since currents in the
winding are adjusted to the ampere turns in the high voltage winding.
Winding technique
Terminals complitely
welded on all conductur
height
Line terminal
Bushings
fixed to
clamps
Al cooling
duct
Winding technique
LV layer winding:
Transposition is a tedious and sensitive process. If not done carefully interstrand faults cause dielectric failures and hot spots in the winding.
Winding is not balanced very well with the High voltage winding. Axial
forces present during short circuit conditions.
Winding technique
Layer Winding
Foil Winding
Winding technique
HV Foil disc winding:
Thin foils of required width are wound with interlayer insulation between
them. Each layer is a turn , so voltage stress is minimized.
Total turns are devided between many discs , so voltage gradient between
discs is also low.
Winding technique
HV Foil disc winding:
Winding technique
HV wire winding:
Multilayer winding , random winding , wire discs winding etc. are some
methods.
Winding technique
Random
Wire discs
Multilayer
Foil discs
Winding technique
Winding technique
What TMC Follows:
TMC follows Foil disc winding technique conisdering its uniform voltage distribution.
Impulse distribution
180
160
140
120
100
Tensione (kV)
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Unfilled system , as the name suggests, does not use any type of fillers. Resin and
Hardner are the main components.
Unfilled system
viscosity.
Fibres needs to be completely impregnated for achieving the desirable dielectric &
mechanical strength.
Fibres , if not impregnated properly , causes voids in the coil that results in dielectric
failures.
This system can be used with good results up 12 kV class. When the voltage stress
is not very high.
Filled system means , resin & hardner are added with fillers like
quartz/silica/aluminium hydroxide etc.
Fillers provide
as
mentioned above.
TMC supplies transformers suitable for storage upto -50 C , which proves
the strength of filled system.
Insulation material used in the filled system are self sufficient for dielectric
strength. Impregantion by resin is not required.
Openwound/Openventilated
windings/VPI/VPE
Impregnated windings
Filled Cast
windings
Unfilled Cast
windings
Windings are made on mandrel ,moulds are fitted, Resin is filled and then
cured.
Cast Coils
reliability.
Low Partial discharges since gap between disc is filled with resin.
LV winding is made with AL/CU Foil. Mould are not used for casting. They
are Impregnated.
Copper Vs Aluminium
Both are used as conductors of electricity & long history of being used as
winding conductors for transformes.
Electrical Properties
Thermal Properties
Mechanical Properties
Copper Vs Aluminium
Copper Vs Aluminium
Electrical Properties:
Copper has lesser resistivity. To achive same ohmic losses 1.5 -1.8 times
higher cross section of Aluminium to be used.
Copper Vs Aluminium
Thermal Properties:
Higher surface area and higher specific heat makes Aluminium coils
cooler than copper coils for same losses.
Copper Vs Aluminium
....contd
This is an advantage for longer life of insulation and also during short time
overloads.
Copper Vs Aluminium
Mechanical Properties :
For Low voltage Foil windings, using preimpregnated insulation and curing
it subsequently makes the coil as a rigid block to withstand forces.
Copper Vs Aluminium
.... contd
Other Considerations:
Price of Copper is very much volatile and ~ 3,5 times of the price of
Aluminium.
Copper Vs Aluminium
What TMC Follows:
Thanks to everybody