PLANNING GUIDE FOR

CAST RESIN TRANSFORMERS

2 PLANNING GUIDE CONTENT

CONTENT
1. RELIABLE QUALITY......................................................................................................................................................................4
1.1. Unique design of the SGB-SMIT layer winding..............................................................................................4
1.2. Decades of experience................................................................................................................................................4
1.3. Areas of implementation...........................................................................................................................................5
1.4. Application areas............................................................................................................................................................6

2. TECHNICAL INFORMATION......................................................................................................................................................7
2.1. General technical data................................................................................................................................................7
2.2. Transformer structure...........................................................................................................................................8-9
2.3. Accessory overview...................................................................................................................................................10

3. ENCLOSURES.................................................................................................................................................................................11
3.1. Standard enclosures........................................................................................................................................... 12-13
3.2. Project enclosures.......................................................................................................................................................14

4. SPECIAL DESIGNS......................................................................................................................................................................15
4.1. Safe System...............................................................................................................................................................15-17
4.2. Jet System.................................................................................................................................................................18-19
4.3. Other designs.........................................................................................................................................................20-21

5. PLANNING INFORMATION....................................................................................................................................................22
5.1. Standards and regulations.....................................................................................................................................22
5.2. Installation conditions..............................................................................................................................................23
5.3. Minimum distances.....................................................................................................................................................24
5.4. Ambient conditions.....................................................................................................................................................25
5.5. Fire behavior..................................................................................................................................................................26
5.6. Seismology...................................................................................................................................................................... 27
5.7. Cooling method................................................................................................................................................... 28-30
5.8. Chassis configurations...................................................................................................................................... 31-32

6. SAFETY DEVICES.......................................................................................................................................................................33
6.1. Grounding........................................................................................................................................................................33
6.2. Temperature monitoring.........................................................................................................................................34
6.3. Electromagnetic compatibility (EMC).............................................................................................................35
6.4. Noise...................................................................................................................................................................................36

7. TRANSPORT.................................................................................................................................................................................. 37
7.1. Lifting lugs on the transformer........................................................................................................................... 37
7.2. Requirements imposed on the truck................................................................................................................38
7.3. oading options for transformers........................................................................................................................38
7.4. Fastening the transformer on the truck........................................................................................................38

8. QUALITY ASSURANCE.....................................................................................................................................................39-40
9. CHECKLIST PLANNING.............................................................................................................................................................41
10. CERTIFICATIONS........................................................................................................................................................................42
 WHO WE ARE PLANNING GUIDE 3

SGB-SMIT AT A GLANCE

1913 3.200 14
HISTORY
... of steadily
EMPLOYEES
... are the key
SITES
We are one of the world’s leading
growing expertise to our success manufacturers of power transformers

READY FOR YOUR MARKET PRODUCTS

The SGB-SMIT Group manufactures • large power transformers
transformers for applications • medium power transformers
worldwide. Sales and service centers • large liquid-immersed distribution transformers
on all continents ensure optimum • liquid-immersed distribution transformers
processes. • dry type transformers
- cast resin transformers
Our products meet the requirements - VPI transformers (conventional and compact core)
in accordance with the applicable • shunt reactors
national standards. • series reactors
• phase shifters
• Lahmeyer-Compactstationen (compact substations)

Transformers from 30 kVA up to incl. 1,200 MVA in

the voltage range up to 765 kV.

QUALITY MANAGEMENT TECHNOLOGIES

The SGB-SMIT Group is certified in Technologies for conventional and
accordance with: renewable energy.
• DIN ISO 9001 • DIN ISO 14001
• DIN ISO 45001
4 PLANNING GUIDE RELIABLE QUALITY

1. RELIABLE QUALITY

1.1. UNIQUE DESIGN OF THE Layer winding design with one or more cooling ducts
• Enlargement of the cooling surface
SGB-SMIT LAYER WINDING • Reduction of internal mechanical stresses
• Improved material utilization
Electrically, layer winding is the best and most • Uniform temperature distribution
reliable technology.

Glass fiber reinforced layer winding cast in pure resin

• The highest level of mechanical stability
and flexibility
1.2. DECADES OF EXPERIENCE
• Significantly more robust with regard to thermal
fluctuations, such as load changes or changes in SGB-SMIT has been producing cast resin
ambient temperatures transformers for more than 30 years – thus SGB-
SMIT has a level of expertise in this field that is
Double-layer winding for linear reduction of surge voltage virtually unrivaled worldwide.
pulses
• For example, for re-ignitions through circuit • Extensive worldwide operating experience,
breakers including international production facilities
• Linear distribution of voltage pulses over the • First-class international references in a wide
entire winding variety of industries
• No appreciable partial voltage overshoots within • Extensive know-how and many years of
the winding experience with onshore and offshore
• Uniform voltage load wind turbines
• Optimal solutions for all industrial applications –
whether simple or highly complex design
• Enclosure design according to your needs
 AREAS OF IMPLEMENTATION PLANNING GUIDE 5

1.3. AREAS OF IMPLEMENTATION

SGB-SMIT cast resin transformers offer solutions
for:

• Extreme environmental conditions:

- Very hot climate zones, e.g. desert regions
- High environmental loads (salt, humidity,
gases)
- Climate zones with extreme low temperatures
(to 50°C), e.g. the Arctic, Siberia

• High short-term overload requirement, e.g. up

to 450 % of rated power

• Moderate long-term loads of up to 140 % of

rated power through use of fans

• Energy grids that claim to be high availability

• Operation in harmonically-loaded grids

• Loads due to switching over-voltages (vacuum

circuit breakers)

• Switching voltages and lightning impulse

voltages

• High demands on mechanical vibration loads

(crane, excavator, earthquake areas, ships)

• Installation altitude to 1,000 m and higher

NEW STANDARDS FOR CUSTOMER BENEFITS

SGB-SMIT cast resin transformers offer a number of features that technically distinguish them from other
cast resin transformers and make them a very reliable and very safe solution.
6 PLANNING GUIDE APPLICATION AREAS

1.4. APPLICATION AREAS

SGB-SMIT cast resin transformers impose the least
demands on the installation site.

Automotive / electro-mobility
Load stations, sub-distribution units and
infrastructure projects

Rail
DC power supply for underground and urban railways

Battery storage and charging stations

„Split powerline“ concepts

Mining
Underground and open-cast infrastructure, crane and
excavator operations

Chemical industry / pharmaceutical industry

Rectifiers and distribution applications for indoor and
outdoor installations

Building technology
For hospitals, schools, department stores, office
buildings, etc.

Power plants / public utilities

„Power to…“ applications

Marine
Ship propulsion systems and shore connections
for ports

Metal and paper industry

Roller drives and pumps

Oil and gas

Refineries, air separation plants, and oil and
gas platforms

Computer centers
Server halls and cooling

Regenerative industry
Photovoltaics, onshore and offshore wind
 TECHNICAL INFORMATION PLANNING GUIDE 7

2. TECHNICAL INFORMATION
2.1. GENERAL TECHNICAL DATA
General implementation spectrum
• Maximum operating voltage: Um = 1.1 to 40.5 kV
• Power spectrum: 50 kVA to 25 MVA (beyond that
possible on request)
• Possible frequencies: 16 2/3; 50; 60 Hz (deviations
possible on request)
• Winding material: Copper or aluminum
• Variable number of systems: 2 to x winders in
concentric or multi-level design
• Based on a selection of basic transformer designs the
transformers can be efficiently adapted or extended
to the respective requirements.

Selection Table – Insulation Level Voltage 12 kV

Power Type P0 Pk 120°C uk LW Length* Width* Height* Total weight*
kVA des. W W % dB (A) mm mm mm kg
400 DTTH1N 750 5500 4 60 1220 820 1770 1450
630 DTTH1N 1100 7600 4 62 1340 820 1950 2000
800 DTTH1N 1300 8000 4 64 1480 820 1980 2450
1000 DTTH1N 1550 9000 6 65 1670 980 1910 2950
1250 DTTH1N 1800 11000 6 67 1750 980 2120 3200
1600 DTTH1N 2200 13000 6 68 1870 980 2250 4250
2000 DTTH1N 2600 16000 6 70 1900 1270 2300 4550
2500 DTTH1N 3100 19000 6 71 2050 1270 2370 5500
3150 DTTH1N 3800 22000 6 74 2270 1270 2520 7450
3160 DTTH1N PEI 99.348 % 6 70 2300 1270 2425 6000

Selection Table – Insulation Level Voltage 24 kV

Power Type P0 Pk 120°C uk LW Length* Width* Height* Total weight*
kVA des. W W % dB (A) mm mm mm kg
400 DTTH1N 750 5500 6 60 1620 820 1830 2100
630 DTTH1N 1100 7600 6 62 1680 820 1990 2950
800 DTTH1N 1300 8000 6 64 1671 820 2000 2650
1000 DTTH1N 1550 9000 6 65 1800 980 2050 3450
1250 DTTH1N 1800 11000 6 67 1970 980 2150 5050
1600 DTTH1N 2200 13000 6 68 2000 980 2390 4750
2000 DTTH1N 2600 16000 6 70 2120 1270 2350 6275
2500 DTTH1N 3100 19000 6 71 2120 1270 2350 6275
3150 DTTH1N 3800 22000 6 74 2310 1270 2720 7770
3160 DTTH1N PEI 99.348 % 6 71 2300 1270 2500 6450

For the tables applies: * Guide values

• Transformers in design in accordance with IEC 60076-11
• Indoor version E2; C2; F1 with tappings 2 x 2.5 % as standard ± (can be changed in de-energized status)
• Dimensions and weights are guide values
• Specified sound power levels apply for AN-mode without enclosure (at no-load)
8 PLANNING GUIDE TRANSFORMER STRUCTURE

2.2. TRANSFORMER STRUCTURE

Plant operators throughout the world appreciate DIMENSIONS AND WEIGHT
the extraordinary reliability of SGB cast resin The quotation, the order documentation or the
transformers, because they get the highest order specification is authoritative for the specific
degree of safety. Unlike oiltransformers, cast resin design of the cast resin transformers. Of course, the
transformers do not have a tank, this means that actual dimensions, such as width, height and weight
the active part is directly visible. of the transformer are specifically dependent on
the respective customer order. This means that the
transformer types shown in the selection list, with
their respective dimensions and weights, can vary
from case-to-case. Dimensional restrictions can be
taken into account in the design and must be made
known in the quotation stage.

Transformer sectional view:

1 Steel clamps 5 Core
2 High-voltage winding 6 Winding support HIGH-VOLTAGE WINDING
3 Low-voltage winding 7 Chassis The high-voltage winding is the heart of the cast
4 Circuit connection resin transformer. SGB-SMIT‘s wealth of expertise
is incorporated in the double layer winding. Our cast
The core (5), held together by steel clamps (1), resin transformers stand out because the wires of
consists of high-quality, grain-oriented, cold- the high-voltage winding are completely embedded
rolled, soft magnetic electrical steel laminations, in a closed cast resin body with a smooth surface.
insulated relative to each other. The distinctive The SGB-SMIT manufacturing technology and the
feature of cast resin transformers is use of high- materials used are characterized by important
voltage windings (2) that are designed as layer unique selling points, which on the one hand
windings completely encapsulated in cast resin distinguish them technically from other cast resin
under vacuum. The low-voltage windings (3) are transformers and on the other hand make them a
usually executed in the form of foil windings. reliable and safe solution.
 TRANSFORMER STRUCTURE PLANNING GUIDE 9

LOW-VOLTAGE WINDING CORE

The low-voltage winding of SGB-SMIT cast resin For calculation of the cores for cast resin
transformers is almost always designed as a foil transformers, no-load losses, noise, and no-load
winding. The advantages of this form of winding current are essential, in many cases crucial, quality
speak for themselves: characteristics.
• High current-carrying capacity The engineering of the core design plays a special
• Balanced temperature distribution in role. This role includes:
the winding • Precise geometric configuration
• High short-circuit resistance • Determination of the material properties of the
There are exceptions for technical reasons, e.g. for magnetic sheet to be used
lower power ratings below 160 kVA and for higher • Design measures to control, for example,
system voltages (Um >7.2 kV). vibrations, inclined positions and other mechanical
requirements
10 PLANNING GUIDE ACCESSORY OVERVIEW

2.3. ACCESSORY OVERVIEW

In addition to the basic components – core,
windings, and mechanical holding frame – additional
equipment is often required to integrate the
transformer into the respective plant.

We offer the following possibilities:

• Castors
• Lift possibility for forklifts
• Locking device
• Transformer bearings
• Machine feet
• Fixed ball points
• Lightning arrestors
• Ground switches, grounding fittings
• Step switch
• Fans (performance increase up to 40 %)
• Enclosure
• PTC and/or PT100 temperature sensors
• Touchless temperature measuring
• Dial thermometer
• Vibration damping through vibration dampers
• Vibration-resistant design
• Earth-quake proof design
• Shield winding
• Switchability (e.g. 20 kV to 10 kV)
• Magnetic bias unit
• Current converters (medium-voltage or
low-voltage)
• Other custom solutions
 ENCLOSURES PLANNING GUIDE 11

3. ENCLOSURES

The portfolio of SGB-SMIT includes different types of enclosures. The selection ranges from various standard
enclosures to enclosures especially adapted to customer requirements.
The enclosures are designed as supporting frame variants.

STANDARD ENCLOSURES PROJECT ENCLOSURES

6 different sizes in different configurations individually adapted according to custom requests

• IP21 - IP33 • IP21 - IP54 possible

• Indoor or outdoor installation • Indoor or outdoor installation
• Floor or chassis installation • Floor or chassis installation
• Doors or hatches • Doors or hatches
• Cooling can be individually adapted
12 PLANNING GUIDE STANDARD ENCLO SURES

3.1. STANDARD ENCLOSURES

Size 1 2 3

Dimension diagram

RSG-no. RSG00000001 - 16 RSG00000017 - 32 RSG00000033 - 48

Dimensions 1,400 mm x 1,000 mm 1,800 mm x 1,200 mm 2,200 mm x 1,400 mm

(L x W x H) x 1,600 mm x 1,900 mm x 2,050 mm

Weight approx. 220 kg approx. 350 kg approx. 425 kg

Protection classes IP 21 / 23 / 31 / 33 21 / 23 / 31 / 33 21 / 23 / 31 / 33

Floor design Floor / chassis Floor / chassis Floor / chassis

Installation type Indoor / outdoor Indoor / outdoor Indoor / outdoor

Inspection designs Hatch / door Hatch / door Hatch / door

1,300 mm x 900 mm 1,700 mm x 1,100 mm 2,100 mm x 1,300 mm
Protective perimeter
x 1,500 mm x 1,800 mm x 1,950 mm
Inlet air surface area
0.30 m² / 0.17 m² 1.27 m² / 0.75 m² 1.67 m² / 0.98 m²
(IP2X / IP3X)

Outlet air surface area

0.35 m² / 0.20 m² 1.47 m² / 0.86 m² 1.93 m² / 1.14 m²
(IP2X / IP3X)

Corrosion protection class C4 C4 C4

Material Dx51D+Z275 (t=1.5 mm) Dx51D+Z275 (t=1.5 mm) Dx51D+Z275 (t=1.5 mm)

Heat dissipation Natural convection Natural convection Natural convection

Powder coating >70 чm >70 чm >70 чm

Color scheme RAL 7035 RAL 7035 RAL 7035

Max. number of inspection

4 6 6
openings

Transformer power
250/10 630/10 1,000/10
Voltage series 10 kV

Transformer power
160/20 315/20 630/20
Voltage series 20 kV
 STANDARD ENCLO SURES PLANNING GUIDE 13

Size 4 5 6

Dimension diagram

RSG-no. RSG00000049 - 64 RSG00000065 - 80 RSG00000081 - 96

Dimensions 2,400 mm x 1,600 mm 2,700 mm x 1,800 mm 3,000 mm x 2,000 mm

(L x W x H) x 2,250 mm x 2,550 mm x 2,800 mm

Weight approx. 505 kg approx. 605 kg approx. 710 kg

Protection classes IP 21 / 23 / 31 / 33 21 / 23 / 31 / 33 21 / 23 / 31 / 33

Floor design Floor / chassis Floor / chassis Floor / chassis

Installation type Indoor / outdoor Indoor / outdoor Indoor / outdoor

Inspection designs Hatch / door Hatch / door Hatch / door

2,300 mm x 1,700 mm 2,600 mm x 1,700 mm 2,900 mm x 1,900 mm
Protective perimeter
x 2,150 mm x 2,450 mm x 2,700 mm
Inlet air surface area
2.17 m² / 1.27 m² 2.80 m² / 1.65 m² 3.52 m² / 2.07 m²
(IP2X / IP3X)

Outlet air surface area

2.49 m² / 1.47 m² 3.24 m² / 1.90 m² 4.07 m² / 2.39 m²
(IP2X / IP3X)

Corrosion protection class C4 C4 C4

Material Dx51D+Z275 (t=1.5 mm) Dx51D+Z275 (t=1.5 mm) Dx51D+Z275 (t=1.5 mm)

Heat dissipation Natural convection Natural convection Natural convection

Powder coating >70 чm >70 чm >70 чm

Color scheme RAL 7035 RAL 7035 RAL 7035

Max. number of inspection

6 6 6
openings

Transformer power
1,600/10 2,500/10 3,150/10
Voltage series 10 kV

Transformer power
1,600/20 2,000/20 3,150/20
Voltage series 20 kV
14 PLANNING GUIDE PROJECT ENCLOSURES

3.2. PROJECT ENCLOSURES

Fabrication of individual enclosures according to
customer requirements is possible in protection
classes IP21 to IP54. For installation, you can choose
between indoor and outdoor installation.

Moreover there is a distinction between floor

and chassis installation. The number of doors
and hatches can be adapted to suit the personal
preferences. Project enclosures can also be
equipped with cooling to dissipate the transformer
thermal power loss.

• AN (Air Natural, convection cooled)

• AF (Air Forced, fan cooled)
• AFWF (Air Forced Water Forced,
air/water cooling)
 SAFE SYSTEM PLANNING GUIDE 15

4. SPECIAL DESIGNS

4.1. SAFE SYSTEM

SGB-SMIT cast resin transformers are characterized
by high reliability, an extremely high level of
protection for personnel, and good environmental
compatibility. New standards were set through the
development of the „Safe System“, particularly for
the new megawatt class of off-shore wind turbines.

Numerous environmental factors can be

accommodated through the Safe System:
• Salty air
• The occurrence of fire
• Vibration in operation and stresses occurring
during transport
• Strong and rapid capacity fluctuations

IMPLEMENTATION SPECTRUM
The Safe System can be delivered up to a maximum operating voltage of Um = 40.5 kV and in the power
range up to 10 MVA. The production capacities are geared to industrial production of several hundred units
per year.
16 PLANNING GUIDE SAFE SYSTEM

GENERAL INFORMATION
The requirements imposed on long-term reliability Protected against salty air
are viewed as the top priority, especially with • Replaceable fans; service life > 5 years
regard to poorly accessible locations, at sea, for • Hermetically sealed against external, salty,
example. With the Safe System, the transformer is corrosive cooling air (DIN EN 50308)
placed in a protective enclosure with an integrated • Extended maintenance intervals because salt
cooler. In the internal cooling circuit, the heat deposits are avoided
caused by the transformer losses is fed to the • Two redundant fans for internal and external
cooler. cooling circuits
• Fan decoupling through non-return flaps
This waste heat is then transferred in the cooler to • Fan with connections on the outside of the
the external cooling medium (water). The re-cooled enclosure
air is returned to the transformer via the internal • Tube cooler made of highly-resistant material
cooling circuit. A significant weight reduction was • Condensation and cleaning water are drained off
achieved by optimizing the cooling system. to the outside
The cooling system is designed in such a manner
that only a small portion of the transformer
thermal power loss is dissipated to the environment
via the enclosure.
 SAFE SYSTEM PLANNING GUIDE 17

Personal protection Fire protection

• Metallic enclosure, IP54, can be dismounted • SGB-SMIT cast resin transformers do not
• Protection against contact with electrically contribute significantly to fire occurrence
live parts (assessment according to IEC 60076-11)
• Inspection openings secured with a locking - Fire classification F1
system - Significantly lower fire load than oil
• Overload or excessive temperature control transformers, for example
through temperature monitoring - No danger of fire propagation through escaping
• Excessive temperature shutdown through liquids
monitoring devices • Effective extinguishing system in the enclosure;
• All parts connected to signal ground; safe coupling with an external fire extinguishing
transformer grounding in de-energized status system is possible
via the grounding switch with first make/last • Arc sensors for fast shutdown of the system
break auxiliary contacts (overload protection)
• Capacitative test and monitoring system • Pressure relief dampers discharge excess
• Lightning arrestors pressure to the outside

Transport and vibration

• Testing by accredited testing institutes
• Core yokes secured by bandages and bolts
• Winding fixation, optionally via a support system
with disk springs
• Windings and holding constructions with
spring elements are exposed and can be easily
retightened if required – a clear advantage over
oil-insulated transformers

Consideration of strong power fluctuations

• High-voltage winding encapsulated in epoxy
resin/glass-fiber insulation
• Expansion of the conductor material and the
resin at load change is accommodated by the
glass fibers embedded in the epoxy resin

Tests in the plant

• Routine test
• Heating measurement
• Surge voltage test with subsequent partial
discharge measurement
18 PLANNING GUIDE JET SYSTEM

4.2. JET SYSTEM

With the Jet System SGB-SMIT offers an optimized

solution for transformers with a cooling system.
Ideal for wind turbines for onshore installation. The
design can be adapted both to installation in the
tower, as well as in the nacelle.

In particular, the following factors, in addition to

life-cycle costs, were taken into account in the
development:
• Optimized cooling
• Protection of personnel
• Fire protection
• Grid connection requirements
• Transport conditions and vibration

Jet System (example in a wind turbine)

1 Air filter (inlet) 6 Enclosure
2 Cold air 7 Hot air
3 Air guide plates 8 Fan
4 Windings 9 Air filter (outlet)
5 Core 10 Tower

IMPLEMENTATION SPECTRUM
The Jet System can be delivered with up to a maximum operating voltage of Um = 40.5 kV and in the power
range from 1.6 MVA to 4 MVA.
 JET SYSTEM PLANNING GUIDE 19

GENERAL INFORMATION Fire protection

The SGB-SMIT cast resin transformer is housed in a • SGB-SMIT cast resin transformers do not
proven IP44 protective enclosure. The cold supply contribute significantly to fire occurrence
air is routed from outside, via a supply air box (1) (assessment according to IEC 60076-11)
and a pipe system, directly to the enclosure (6). - Fire classification F1
By means of an air guide plate (3), the cooling - Significantly lower fire load than is the case
air (2) is directed specifically into the ducts of the with oil transformers
winding (4). - No danger of fire propagation through escaping
liquids
The exhaust air heated by the transformer thermal • Arc sensors for fast shutdown of the system
loss is blown directly into the open air via a pipe • Hot gases can escape via aeration and ventilation
system, which also houses a low-noise fan (8). lines
The result is a defined cooling system that can be
tested in a factory test. Grid connection requirements
Grid connection conditions have a considerable
The no-load losses and low-load losses that influence on the design of a transformer.
occur with a load of up to 30 % rated power, can
be dissipated without switching on the fan. At By using the optimized cooling of the transformer
higher load, the fan is switched on via temperature and through ducts in the windings, and the
sensors in the windings. configuration of the magnetic core, we have
succeeded in significantly reducing the additional
In this, the directed air flow results in a low heating material required to meet the grid connection
of the windings. Thanks to the optimized design requirements.
of the cooling system considerable savings in
material and space requirements can be achieved. A certain amount of inductive and capacitive
reactive power must be transmitted through the
Temperature range from -25 to +40°C transformer.
(special cases: Temperatures to -50°C and +50°C)
Transport and vibration
Environmental class E2 (tested by the institute) • Core yokes secured by bandages and bolts
For higher requirements it is possible to fit the • Winding fixation, optionally via a support system
device with appropriate filters. with disk springs
• Windings and holding constructions with
Personal protection spring elements are exposed and can be easily
• Metallic enclosure, IP44, can be dismounted retightened if required – a clear advantage over
• Protection against contact with electrically oil-insulated transformers
live parts
• Overload or excessive temperature control
through temperature monitoring
• All parts connected to the grounding system of
the plant
20 PLANNING GUIDE OTHER DESIGNS

4.3. OTHER DESIGNS

TWO-LEVEL TRANSFORMER NEUTRAL GROUNDING TRANSFORMER
Two-level transformers consist of two high- A neutral grounding transformer is used for
voltage windings that are switched in parallel, and realization of the missing neutral point in electrical
two independent low-voltage systems. distribution networks or if the transformer neutral
points cannot be fully loaded. However neutral
The most common use of two-level transformers grounding transformers are also used to extinguish
is to supply a 12-pulse rectifier that is connected to a ground fault or to limit the ground fault current via
the low-voltage systems. its impedance. Usually they are connected between
larger power transformers and the ground.
In addition to the classic two-level application
there is also the version as so-called mechanical There are neutral grounding transformers that are
two-level. This design is used when the current only operated in short-term operation, for example
of the low-voltage systems is so high that it can for 10 seconds as long as a fault current occurs.
no longer be handled with a single low-voltage Short-circuit losses are also generated here only
winding. To control the high current, two low- for the 10 seconds.
voltage windings, that are arranged axially are
switched parallel. However, there are also cases, in which current flows
permanently via the neutral point transformer. This
current is in the range of 10-20% of the maximum
fault current. The customer specifies the operating
mode, rated power, switch group, and impedance.
 OTHER DESIGNS PLANNING GUIDE 21

DUAL INDUCTOR
A dual inductor is initially only used for grid
coupling with compensating current limitation.

The SGB-SMIT dual inductors have two windings

per strand, one main winding and one auxiliary
winding. At their connection point, additional
energy can be injected from a transformer or
generator (e.g. emergency power generator).

Among other things, the dual inductor prevents

current from flowing into a collapsing power
grid before a (fast-opening) switch that is usually
located on the grid side upstream of the dual
conductor can be opened. The occurrence of
major short-circuit currents to the power grid is
prevented here by the dual inductor.

Other functions:
• Filter function in conjunction with generator and
transformer
• Safe weakening of grid-side voltage peaks
• Significantly reduced transmission of grid-side
voltage harmonics to the consumer side
• Drastic reduction of load-side current harmonics
on the grid-side

... AND MUCH MORE...

22 PLANNING GUIDE PL ANNING INFORMATION

5. PLANNING INFORMATION

5.1. STANDARDS AND REGULATIONS

SGB-SMIT cast resin transformers fulfill the OTHER REGULATIONS
requirements specified in the customer order The following regulations must also be complied with
in accordance with national, European, and when constructing and operating installations:
international standards. • DIN VDE 0100 (Erection of Power Installations
with Nominal Voltages Up To 1000 V)
REGULATIONS • DIN VDE 0105-100 (Operation of Electrical
• 2009/125/EU (Ecodesign Directive) Installations)
• 548/2014 (Commission Regulation EU) • DIN VDE 0100-718 (Erection of low-voltage
installations - Requirements for special
STANDARDS IN THE EUROPEAN UNION installations or locations - Communal facilities and
• DIN EN 60076-1 (Power transformers) workplaces)
• DIN EN 60076-11 (Dry-type transformers) • EltBauV (Ordinance on the construction of
electrical operating areas)
• ArbStättV (Regulations for the Workplace
STANDARDS OUTSIDE THE EUROPEAN UNION Ordinance)
• IEEE (Institute of Electrical and Electronics
• TA-Lärm (Instructions for protection against noise)
Engineers - USA)
• CSA (Canadian Standards Association - Canada)
• GOST (Gossudarstwenny Standart - Russia) OTHER PLANNING AND
• GB Standard (China) CONFIGURATION INFORMATION
• VDI 2078 (Calculation of thermal loads and room
temperatures)
• Customer specifications
 INSTALL ATION CONDITIONS PLANNING GUIDE 23

5.2. INSTALLATION CONDITIONS

• Indoor installation is intended Extreme installation conditions must be
• Degree of protection IP00; winding surfaces are communicated for correct Installation planning,
not safe to touch e.g.
• Enclosure mandatory for outdoor installation, • Installation altitudes higher than 1,000 m above
minimum degree of protection IP23C sea level
• Installation with medium-voltage and low- • Ships
voltage switchgear is possible in one room; short • Earthquake zones
connection paths • Wind turbines
• No protective measures necessary for • Extreme temperature conditions (extremely
prevention of water pollution because there is cold, tropical, etc.)
no need for oil as the insulation fluid • Special installations – communal facilities and
• No additional measures required for fire workplaces (DIN VDE 0100-718)
protection and oil trays • EX areas
24 PLANNING GUIDE MINIMUM DISTANCES

5.3. MINIMUM DISTANCES

In particularly confined spaces, such as in protective The windings of the cast resin transformers are not
enclosures, the minimum distances must be safe to touch in spite of the cast resin insulation.
complied with to prevent arcing. Cast resin insulation is a functional insulation. This
insulation offers no protection against dangerous
When planning any tasks in the vicinity of the shock currents when touching or against electrical
transformers, note that the „protective perimeter“ flashovers when the transformer is approached.
does not prescribe the limits of the danger zone as Take protective measures to prevent people from
defined by DIN EN 50110-1, but only the distance entering the danger zone of the windings.
required for trouble-free operation.

Voltage Lightning Minimum air gaps /

Um surge minimum distances to grounded
voltage LI conductive parts
(kV) (kV) A (mm) B (mm) C (mm)

1,1 - 40 20 40
3,6 20 60 30 60
3,6 40 60 30 60
7,2 60 90 45 90
7,2 75 120 65 120
12 75 120 65 120
12 95 160 85 160
12 110 200 115 200
17,5 95 160 85 160
17,5 125 220 115 220
24 125 220 115 220
24 145 270 140 270
24 150 270 140 270
36 170 320 160 320
36 200 380 180 380
40.5 200 380 180 380

All values apply to installation altitudes ≤ 1000 m above sea level

A = Distance to the high-voltage winding connection
B = Distance to surface of the outer encapsulated winding
C= Distance to the low-voltage winding connection

PLANNING INSTRUCTION
When planning and implementing protective measures, treat the windings as unprotected live parts!
 AMBIENT CONDITIONS PLANNING GUIDE 25

5.4. AMBIENT CONDITIONS

Cast resin transformers are rated in different climatic and environmental classes. The required classes must
be determined by the plant operator. Configurations up to class C2 and E2 according to IEC are possible as
standard, higher classes must be requested.

CLIMATE CLASSES
The climate class takes into account the lowest ambient temperature during transport, storage, and operation.

Class C1 Class C2 Class C3 Class C4 Class C5 Class Cxy*

Transport & storage
In accordance with IEC -25°C -25°C -40°C -50°C -60°C -X°C
In accordance with GOST -25°C -25°C -45°C -60°C - -
Operation
In accordance with IEC -5°C -25°C -25°C -40°C -50°C -Y°C
In accordance with GOST -5°C -25°C -45°C -60°C - -
*The temperatures -X °C and -Y °C can be agreed on a project-specific basis.

ENVIRONMENTAL CLASSES
Air humidity, dripping water, condensation, and Class E1:
contamination are among the environmental Occasional condensation may occur on the
influences for dry-type transformers. These transformer (for example when the transformer is
influences are important not only during switched off). Contamination to a limited extent is
operation, but also during storage before possible.
the transformer is installed. With regard to
these different environmental conditions, five Class E2:
environmental classes are defined according to Frequent condensation or light contamination or a
IEC 60076-11 for transformers without special combination of both.
external protective measures.
Class E3:
Class E0: Frequent condensation or medium contamination or
Condensation does not occur on the transformer, combination of both.
contamination is negligible. This condition is usually
achieved when installed in a dust-free and dry Class E4:
interior space. Frequent condensation or light contamination or a
combination of both.

CONCLUSION
SGB-SMIT cast resin transformers are thus safe to operate in conditions that involve condensation as well
as contamination. However, the maintenance intervals should be adapted to the ambient conditions. This
means that we recommend cleaning the winding surfaces if there is heavy contamination. Likewise, they
are suitable for outdoor installation at temperatures to -50°C with a protective enclosure, starting with
IP23, with special paint finish.
26 PLANNING GUIDE F I R E B E H AV I O R

5.5. FIRE BEHAVIOR

FIRE CLASSIFICATIONS FIRE SAFETY
The required fire classification must be specified by Since SGB-SMIT cast resin transformers only have
the plant operator. However, SGB-SMIT cast resin cast resin components in the LV and HV windings,
transformers always meet the highest defined the fire load is essentially determined by these
class F1. components.

Class F0: FIRE GAS ANALYSIS

• No specific fire risk is taken into account. In the laboratories of ALLIANZ AG, the casting resin
• No special measures to limit the fire hazard, with molding material from an SGB transformer winding,
the exception of fire hazards due to the design of as well as samples of all insulating materials were
the transformer. carbonized and the combustion gases analyzed.
• Release of toxic substances is limited to a
minimum. • The possibility of dioxin formation is excluded
• The possibility of sulfur dioxin formation is
Class F1: excluded
• Limitation of the fire hazard is taken into account. • Smoke gas consists mainly of carbon monoxide,
• Release of toxic substances and vision-obstructing carbon dioxide, steam, and soot
smoke is reduced to a minimum. • Trace fractions of other hydrocarbons
• SGB-SMIT cast resin transformers do not
contribute significantly to the fire.

Comparison of fire load – cast resin transformers and liquid-cooled transformer types for 1000 kVA design:

Transformator type Insulation quantity [kg] Calorific value [kWh/kg] Fire load [kWh]

Cast resin 150 8.2 1230

Mineral oil* 700 12.9 9030

Silicone oil* 800 8.5 6800

*Only insulation fluid is considered

RESULT
The results of the investigation show that the casting resin molding material that we use is to be classified
as harmless.
 SEISMOLOGY PLANNING GUIDE 27

5.6. SEISMOLOGY
If the transformer is installed in a seismically active region, the possible external mechanical stress must be
taken into account in the design.

You determine the seismic class. The determination

can be made using the following steps:

1st Step:
Determine the relevant zone of earthquake activity
according to IEC 60721-2-6.

2nd Step:
Select the ground acceleration of the relevant
earthquake activity zone according to IEC 60721-2-6.

3rd Step:
Select the seismic class based on the ground
acceleration (see the table below).

IEC 60076-11 describes three different seismic

classes.

Seismic Earthquake Ground acceleration AG Richter scale MSK scale

class [m/s²]
From earth
S-I tremors to medium 2 < 5.5 < VIII
earthquakes
For medium to strong
S-II 3 5.5 bis 7.0 VIII bis IX
earthquakes
For strong to very
S-III 5 > 7.0 > IX
strong earthquakes
28 PLANNING GUIDE COOLING METHOD

5.7. COOLING METHOD

The site where the cast resin transformer is installed NATURAL AIR CIRCULATION
must be sufficiently ventilated, as every time the • Always provide the inlet opening of the supply
transformer is operated there is heat loss, which air at the bottom and with a maximum height up to
must be discharged out of the equipment room. the beginning of the LV winding. This promotes the
chimney effect and circulation of the air flow in the
Here it is necessary to check whether the possibility duct between the windings.
of natural aeration and ventilation is provided. If the • If possible, arrange lower openings for supply air
dimensions of a room or enclosure do not ensure entry all around the transformer.
proper cooling, the air flow must be ensured by • Cross-section for the upper opening normally 10
forced ventilation. to 15 % larger than the lower openings. This takes
into account the lower density of the exhaust air.

The volume required for proper cooling can be

Symbol calculated as follows:
Air A
Cooling medium
Water W
Cooling medium Natural N
movement Forced F The effective area of the lower opening can be
calculated as follows:

The ventilation system must be dimensioned for

the maximum heat loss that occurs. This consists of
the no-load losses of the iron core and the thermal KEY:
energy generated by the windings. Pt: Total losses to be removed in kW
ΔO: Temperature gradient in K between supply and return
air / empirical value approx. 15°C
Q: Air volume flow in m³/s
H: Distance in meters between the centerline of the
transformer and the centerline of the upper opening of
the cell
S: Useful area of the lower supply air opening
(without grille) in m²
 FANS PLANNING GUIDE 29

FORCED AIR CIRCULATION WITH FANS Installation of the cast resin transformer in an
Cast resin transformers can be equipped with enclosure with protection class ≤ IP33
fans to increase performance. Through the forced If the cast resin transformer is installed in an
cooling, an increase in performance of up to 40% is enclosure, or if it stands in a more or less closed
possible. With an optimum configuration, a higher room, sufficient ventilation must always be ensured.
value can also be achieved. For enclosures, this mainly depends on the selected
degree of protection.
The following variants are available for forced
cooling of cast resin transformers: The air guide plates (1) are made to cover the
air space between the enclosure wall and the
Freestanding cast resin transformer transformer. When the fan (2) is in operation, it
• Attachment of 2 to 6 fans on the lower steel ensures that the cool outside air is drawn through
clamps on both the high-voltage and low-voltage the transformer and its windings. In this case as
sides of the transformer. well, additional fans can be mounted that can be
• Fans are intended for short-term operation. switched on as required.
If continuous operation is required, this must be
specified.

• This is the usual situation when the transformer is

installed without an enclosure. If the solutions presented here do not meet your
• The average power increase in this case is 40%. requirements, we would also be pleased to work
This means that for a cast resin transformer with with you to develop customer-specific solutions.
a 1000 kVA AN (natural cooling) power rating, a
power rating of 1400 kVA can be assumed if fans Please contact us.
are used.

SGB-SMIT has proven this performance increase

with fans in many test runs.
30 PLANNING GUIDE COOLING AIR TEMPERAT URE

COOLING AIR TEMPERATURE

Climatic conditions, such as extreme cold in winter If the ambient temperatures deviate from the
or strong solar radiation in summer, must be taken values defined in the standard, these temperatures
into account. The transformer room must be air- should be communicated so that this can be taken
conditioned accordingly. into account in the transformer design. If, for
example, higher ambient temperatures are not
In air-conditioned rooms, avoid blowing the cooled taken into account, this can have a negative effect
air from the air-conditioning system directly on the service life.
onto the hot windings. This extreme temperature
difference can cause cracks in the windings, which in
the worst case can result in failure of the cast resin Ambient temperature Transformer load
(annual average) capacity
transformer.

If the cooling air is heavily contaminated, it may -20°C 124%

have to be filtered.

Cast resin transformers are designed according to

the relevant standards for the following cooling air -10°C 118%
values:

The temperature of the cooling air does not exceed: 0°C 112%
• 40°C (at any time)
• 30°C in the monthly average of the hottest month
• 20°C annual average
+10°C 106%

The temperature of the cooling air does not fall

below the standard value:
• -25°C for outdoor transformers +20°C 100%
• -5°C for indoor transformers

Lower temperatures are possible on request. +30°C 93%

 CHASSIS PLANNING GUIDE 31

5.8. CHASSIS CONFIGURATIONS

The chassis is available in different track widths. It can be equipped with castors or machine feet. We would also
be pleased to develop customer-specific solutions.

*Standard sizes; customer-specific track widths are possible on request

CASTORS
The castors are available in different heights and materials. To protect against rolling off, locking devices are
provided.

Castors (4 castors / transformer) Height [mm] Material Max. load capacity

125 Plastic 2.5 t

125 Steel 2.5 t

160 Steel 3.6 t

200 Steel 6.3 t

Locking device for castors

Height [mm]
(2x / transformer)
125

160

200

200 with flat roller

32 PLANNING GUIDE CHASSIS

The direction of the castors is adjustable. Depending TRANSFORMER BEARINGS

on how the castors are attached on the chassis, For the bearing arrangement of transformers
the transformer can be moved longitudinally or directly on the ground, or on non-insulated
transversely. movement rails, the vibration emanating from the
transformer generates unpleasant noises and
undesired vibration in the environment.

Transformer bearings are used for protection of

rolling away and damping of noise and vibration
emanating from the transformer.

Noise and vibration damping is achieved through

structural separation of the lower part and upper
part via a special damping element. The weight of
the transformer compresses the rubber, resulting
in transverse vibration damping and horizontal
damping.
MACHINE FEET
The machine feet simultaneously act as vibration The transformer bearing is selected in accordance
dampers. Moreover, they also insulate against with the load capacity. If there is increased
noise. The rubber element in the vibration damper mechanical stress, e.g. when used on ships and
withstands up to max. 5100 kg. excavators, in wind turbines, in earthquake regions,
etc., additional design measures are necessary.
When installing the transformer on a rubber
bearing, the spring deflection must be taken
into account, as this can change the position of
the connections somewhat. This is critical when
connecting transformers to existing rail systems.

Cross section of a machine foot

Transformer bearings
 SAFETY DEVICES PLANNING GUIDE 33

6. SAFETY DEVICES

6.1. GROUNDING
Grounding (equipotential bonding) of the core and In addition, grounding switches can be mounted on
the metal parts of the cast resin transformer always the LV connection side and on the HV connection
occurs. A connection for grounding to the chassis side of the windings, or on the wall in the course of
is provided as standard equipment. Customer the HV cable connection.
desires can of course be taken into account, such as
grounding on the steel clamps. The grounding or equipotential bonding on the
transformer must be properly connected or
Fixed ball points can be attached to the conductor checked. In this regard the tightening torques of the
connections to ground the windings when the mounting screws and the minimum cross-sections
transformer is disconnected: of the potential equalization conductors must be
• 20 mm diameter complied with. The cross-section of the potential
• 25 mm diameter equalization conductor must be at least half as
• Straight large as the protective conductor cross-section of
• Angled the installation, but no less than 6 mm² copper for
mechanical reasons.

Assignment of the minimum cross-sections of

protective conductors and neutral conductors to
the cross-section of the outer conductors according
to VDE 0100-540.
34 PLANNING GUIDE TEMPERAT URE MONITORING

6.2. TEMPERATURE MONITORING

• On customer request, PT100 and core monitoring
by means of PT100 or PTC sensors is also
possible.
• Touchless temperature measuring is also
available.

As a rule, monitoring takes place in two stages:

Touchless temperature measuring

Under certain conditions, any cast resin

transformer, just like liquid-filled types, can be
overloaded.

Warning
The temperature monitoring system limits the
This system signals the overshoot of the
overload capacity of cast resin transformers
temperature that is the basis of normal service
by switching off the transformer at a specified
life consumption, i.e. continuous rated load at 20°C
nominal response temperature.
cooling medium temperature. It is intended to warn
the plant operator and motivate the plant operator
Temperature monitoring by means of PTC sensors
to implement off-load measures.
(resistors whose resistance value changes
rapidly when the response temperature is
Tripping
reached) is generally provided for each cast resin
This second system is adapted to the limit
transformer. Sensors are installed in the low-
temperature of the declared temperature class.
voltage windings and by selecting the appropriate
In this case the transformer must be switched
tripping temperatures, the vacuum-encapsulated
off. Operation at excessive temperature shortens
high-voltage windings are also protected against
the service life. The lines of the three resistors
unacceptably high temperatures, which can occur
(here 1 sensor per phase) are connected in series
in the event of overload, inadequate cooling, and
to a terminal strip. From this point a two-wire
high ambient heat.
connection is made to the analysis unit, which
is supplied loose for free installation in the
switchgear.
 ELECTROMAGNE TIC COMPATIBILIT Y PLANNING GUIDE 35

6.3. ELECTROMAGNETIC COMPATIBILITY (EMC)

Transformers generate electrical and magnetic For connection of the transformer, field
fields during operation. These electromagnetic compensation through double low-voltage
fields can reach values for which the Federal conductor routing with point-symmetrical phase
Emissions Control Act (BImSchG) applies. assignment is recommended, if it is required.
According to IEC 60076, transformers are
Limit values of a low-frequency installation with considered as passive elements with regard to
50 Hz fields at the point of exposure* according to electromagnetic emissions and immunity and CE
specification 26. BImSchV: marking is not permitted.
• 5 kV/m electrical field strength
• 100 µT magnetic induction According to measurements and calculations,
*The place of impact is the place with the highest exposure, where a the magnetic field around SGB-SMIT cast resin
not just temporary presence of personnel must be expected.
transformers is considerably below the limit value
set by the 26th Ordinance on the Implementation of
The electric field outside the cast resin transformer the Federal Immission Control Act (26th Ordinance
and its connections is not very effective outside of the Federal Republic of Germany).
the transformer cell. The protective enclosure
of SGB-SMIT cast resin transformers acts as a Under defined measuring conditions, the
Faraday cage. This also applies to a great extent magnetic field of a cast resin transformer, e.g.
for the ceilings and walls of the transformer cells, 630 kVA / 20 kVA–0.4 kV, is approx. 5 µT according
provided they are not made of electrical insulation to our own measurements at a distance of 2 m from
material. the cast resin surface of the winding.

The magnetic stray fields of the transformer, Technical interference limits for the following are:
which essentially consist of three sources, can give • Cardiac pacemakers 50 Hz, 4 – 6 µT
rise to interference: • Hearing aids 50 Hz, 2 – 20 µT
• Stray field at idle • ECG 50 Hz, 0.4 µT
• Stray field from the connection lines
• Stray field from current-carrying windings The 26th BImSchV applies to „Stationary
installations for transformation and transmission
The idle stray field is negligible. The windings of electricity“. It covers in its field of application
through which the load current flows generate „Electric substations, including control panels,
the largest portion of the stray field, which is with a frequency of 50 Hz and a maximum voltage
superimposed by fields of the undervoltage-side of 1 kV or more“. Since power transformers must be
arrestors. viewed as components of an overall system, i.e. of
an appropriate installation, they are excluded from
The magnetic field around low-voltage connections this regulation.
dominates the level of the entire field.
36 PLANNING GUIDE NOISE

6.4. NOISE
AIRBORNE SOUND
The airborne sound is dependent on:
• Total surface of the transformer room
• Surface of the transformer
• Sound absorption of building materials used

Reduction of airborne noise:

• Reduction of sound reflection by lining the
transformer room e.g. with slag wool
• Reduction of sound pressure level outside the
transformer room via a thick outer wall
• Continuous reduction of sound pressure level with
Step lap
increasing distance

Noise is generated by magnetostriction of the core STRUCTURE-BORNE SOUND

metal sheets. It is mainly dependent on induction in Structure-borne sound is a transmission of noise via
distribution transformers. The reduction of noise the contact surface of the transformer to the floor
emitted into the surrounding air of the transformer to walls and other parts of the transformer room.
is becoming more and more important. SGB-SMIT
cast resin transformers are therefore offered both Reduction of structure-borne noise:
in standard design, according to DIN EN 50588, and • Expansion straps interposed at the undervoltage
with reduced losses and noise. connection to protect against structure-borne
noise transmission.
In addition to the choice of induction and core • Structure-borne sound insulation for optimizing
material, the tapering of columns and yokes in the room insulation, e.g. transformer bearings,
„step lap“ process has a positive effect on the noise machine feet
behavior of the transformers.

Sound pressure and sound power levels, and the

manner in which the noise measurement must be
carried out are specified in DIN EN 60076-10.

The operating noises of the cast resin transformer

propagate on site as airborne and structure-borne
noise, with different sound reduction measures
being applied for each form of sound.
 TRANSPORT PLANNING GUIDE 37

7. TRANSPORT

7.1. LIFTING LUGS ON THE TRANSFORMER

There are four lifting and lashing lugs on the upper
steel clamps.
Version 1
The lifting lugs (1) are located at the outer edges of
the upper steel clamps.
In this version, the lifting lugs also serve as lashing
lugs.

Version 2
For larger transformers it is possible to have lashing
lugs and lifting lugs separate from each other. In
these cases, the lashing lugs (2) remain on the outer
edges of the steel clamps. The lifting lugs (1) are
arranged in the middle.

Lifting lugs and lashing lugs on the upper steel clamp

1 Lifting lugs for lifting the transformer

2 Lashing lugs
38 PLANNING GUIDE TRANSPORT

7.2. REQUIREMENTS IMPOSED 7.4. FASTENING THE TRANSFORMER

ON THE TRUCK ON THE TRUCK
Transport vehicles must meet the requirements The load must be positioned and the inertial forces
listed here: occurring during transport must be contained.
• Technically faultless condition When driving, the load is subjected to stresses
• Comply with all statutory regulations that act longitudinally (forces from acceleration
• Air suspension and braking processes), transversely (forces from
• Closed construction (tarpaulin vehicle) cornering) or vertically (forces from driving over
• Can be loaded from above (it must be possible uneven ground) in relation to the direction of
to temporarily dismantle the superstructure and travel.
tarpaulin)
• For each transformer to be transported, use Transformer is fastened with four lashing lugs
at least four lashing straps (according to (accessories of the forwarding company or truck)
DIN EN 12195-2) and four anti-slip mats at least to four lashing lugs of the upper steel clamps with a
8 mm thick tensioning angle of approx. 30 degrees downwards
• Have a sufficient number of lashing lugs (at least to the existing lashing lugs of the truck.
four per transformer)
Select load securing equipment in accordance with
DIN EN 12195-2.
7.3. LOADING OPTIONS
FOR TRANSFORMERS
• With crane
• With forklift for special chassis design

Lashing the transformer:

1 Lashing lug on the transformer
2 Lashing lugs of the truck
 QUALITY ASSURANCE PLANNING GUIDE 39

8. QUALITY ASSURANCE

INHOUSE TEST FACILITIES

In the standard situation SGB-SMIT cast resin
transformers are designed and manufactured
according to IEC 60076-11. At SGB-SMIT the tests
specified in the standard are carried out in our own
modern test facility:

Routine tests
• Testing with applied withstand AC voltage
• Voltage ratio measurement and phase shift
control
• Measurement of winding resistance
• Testing with induced withstand AC voltage
• Partial discharge measurement
• Measurement of no-load losses and no-load
current
• Measurement of short-circuit impedance and
short-circuit losses
• Checking the temperature sensors

Type tests
• Lightning impulse voltage test with Marxgenerator
up to 400 kV and 20 kJ charging energy
• Heating measurement
40 PLANNING GUIDE QUALITY ASSURANCE

Special tests SGB-SMIT cast resin transformers are supplied to

Measurement of the harmonic oscillations of the more than 50 countries – the relevant standards in
no-load current in % of the fundamental oscillation these countries, such as ANSI, IEEE, GOST, etc. are
• Measurement of the magnetizing characteristic used as a basis for design, manufacture, and testing.
curve
• Measurement of commutation reactance DETAILED TESTS IN EXTERNAL INSTITUTES
• Measurement of insulation resistance Together with external institutes, we can also carry
• Partial discharge measurement out detailed measurements for important technical
• Determination of the A-weighted no-load noise areas:
level using the sound pressure method • Fire behavior test (destructive test)
• Determination of the capacities of the windings • Dynamic short-circuit test according
against earth and between the windings, as well as to IEC and GOST
the loss factors (tan ∂) • Electromagnetic compatibility EMC
• SFRA (Sweep Frequency Response Analysis) • Fire gas analysis or smoldering gas analysis
• Measurement of the electrical resonance • Vibration-resistant design
frequency
• Measurement of structure-borne sound (vibration
measurement)

Noise measurement
• The noise measuring chamber has a length of 10 m
and a height of 5 m. The basic level is 37 dB(A).

Verification of climate and environmental class

• Test possibility up to climate class C5
• Test possibility up to environment class E4

PARTICULARITY
SGB-SMIT is the first transformer manufacturer worldwide with its own test facility for climate
classes and environmental classes.
 CHECKLIST PLANNING PLANNING GUIDE 41

9. CHECKLIST PLANNING
PLANNING MEASURES
(Notes from IEC 60076-11)

Restrict access to transformer to avoid contact with live or hot parts and to limit the presence of
persons in the event of a fault.

Dimension the cooling system sufficiently to keep the ambient air temperature below the specified
maximum limits.

Observe the degree of pollution of the ambient air of the transformer (possibly provide an enclosure
to protect against dust, salt, moisture, etc.).

Ensure the ventilation function of the protective enclosure.

Plan for sufficient protection against transient over-voltages generated by the system or by lightning.

Determine the overcurrent protection and the inherent short-circuit resistance of the transformer.

Comply with other protective measures on the transformer (contacts on temperature indicators, etc.)
and during installation (relays, fuses, etc.).

Consider the danger and consequences of fire from the transformer itself or that originates from
another location. Take all possible precautions.

Limit noise emissions outside the installation.

Avoid the formation and accumulation of gases.

Ensure protection against emissions from magnetic fields (mainly from cables or outlets) outside the
installation by means of shielding elements in the installation or through sufficient distances.

The list is not exhaustive. These are merely proposals.

42 PLANNING GUIDE CERTIFICATIONS

10. CERTIFICATIONS
SGB not only satisfies the standards regarding production technology and occupational health and safety, but also has
high self-imposed standards and takes the challenge also in environmental matters – which is highlighted by awards
and certificates issued by various institute

TÜV ISO 9001 FSK

Quality and performance Requirements of the Russian
grid company

TÜV ISO 14001 JSC VNIIAM

Environmental protection Requirements of the Russian
nuclear industry

TÜV ISO 18001 UL

Occupational Safety and Health American Quality and
Safety Requirements

DNV GL WIND ONSHORE F1-CESI

Certification for suitability Fire protection class
in onshore wind turbines

DNV GL WIND OFFSHORE C2/E2 KEMA AND CESI

Certification for suitability Climate and environment class
in offshore wind turbines

GOST
Satisfies Russian quality and
safety requirements All certificates are renewed
on a regular basis
 CAST RESIN TRANSFORMERS PLANNING GUIDE 43

Up to and incl. Up to and incl. Up to

25MVA
POWER
36KV 200KV
O P E R AT I N G V O L TA G E BIL
 STARKSTROM-GERÄTEBAU GMBH SGB-SMIT SALES INC.
Regensburg • Germany Summerville, SC • USA
Phone +49 941 7841-0 Phone +1 843 871-3434

SÄCHSISCH-BAYERISCHE SGB-USA INC.

STARKSTROM-GERÄTEBAU GMBH Tallmadge, OH • USA
Neumark • Germany Phone +1 330 472-1187
Phone +49 37600 83-0
OTC SERVICES INC.
ROYAL SMIT TRANSFORMERS B.V. Louisville, OH • USA
Nijmegen • The Netherlands Phone +1 330 871-2444
Phone +31 24 3568-911
SGB MY SDN. BHD.
SMIT TRANSFORMER SERVICE Nilai • Malaysia
Nijmegen • The Netherlands Phone +60 6 799 4014
Phone +31 24 3568-626
SGB TRANSFORMERS INDIA PVT. LTD.
RETRASIB S.A. Chennai • India
Sibiu • Romania Phone +91 44 45536147
Phone +40 269 253-269
SGB CHINA
SGB CZECH TRAFO S.R.O. Changzhou • P.R. China
Olomouc • Czech Republic Phone +86 519 82999000
Phone +420 605 164860
SGB-SMIT POWER MATLA (PTY) LTD.
BCV TECHNOLOGIES S.A.S. Pretoria West • South Africa
Fontenay-le-Comte • France Phone +27 12 318 9911
Phone +33 251 532200 Cape Town • South Africa
Phone +27 21 505 3000

STARKSTROM-GERÄTEBAU GMBH
Ohmstraße 10 • 93055 Regensburg • Germany
Phone +49 941 7841-0
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Fax +49 941 7841-439

e-mail [email protected]

www.sgb-smit.com