0. SGB at a glance
One of the leading manufacturers for transformers worldwide
SGB Regensburg
 50 kVA up to MVA
 turnover (2010): ~ EUR 580 million  employees  Headquarters: Regensburg, Germany  5 production plants worldwide
SBG Neumark
SGB USA Inc.
AM SGB
SMIT
Apr-17

1. SGB-SMIT Group: steadily growing expertice
1993
1994
2000
2010
1947
1990
2008
2009
2010
AM SGB Formation
TRR Acquisition
SBG Formation
SGB-CR Formation
SGB-USA Formation
SGB Formation
SMIT Acquisition
STS Formation
580 Mio €
STS
SGB-USA
SGB-CR
SMIT
Employees, incl. trainees :
AM SGB
Umsatz
SGB – SMIT Gruppe
0,65 Mio €
SBG
TRR
SGB
Apr-17
Chart 1

2. SGB global presence cast coil transformers
SGB USA Inc.
Xintai
DTPL, India
Nilai
SGB Locations
in Europe, North America and Asia.
Apr-17

3. Range of Application
Transformer
SMIT
Large Power
(for power plants and substations)
SBG / AMSGB
Oil-Distribution
(for local grids; transformer stations)
SGB
Medium Power
(for substations)
SGB / AMSGB
Cast Resin
(for industry,wind power,
marine appl.)
Voltage / Capacity kV
220 kV
110 kV
30/20/10 kV
400/240 V
150 – MVA
10 – 150 MVA
50 KVA – 30 MVA
Power Plants
High Voltage
Medium Voltage
Low Voltage
Customers
Energy Companies
Energy Companies, Grid Companies, Industry
Industry, Local Energy Supplier, Marine application
Industry, Local Energy Supplier, Public Utilities
The group covers the complete transformer programme.
Apr-17

4. Cast Resin Transformers
SGB Regensburg
Types
2- and 3-winding transformers
acc. to VDE 0532 / IEC 726
Special transformers:
Rectifier transformers
Reactances
others
Cast Resin Transformers
Service voltage up to incl. 36 kV
BIL up to incl. 200 kV
Rated power 50 kVA – 30 MVA
Apr-17

5. SGB Regensburg Marine applications Public Utilities
Markets for Cast Resin Transformers
Marine applications
Public Utilities
Large industrial energy users Ä Automobile industry Ä Chemical industry
Regional and national transport systems
Plant contractors Ä Industrial plants Ä Power supply networks and substations
Internet Centers
Wind power facilities (on-/offshore)
Apr-17

6. SGB transformers for ships and oil rigs
Phase Shift for drive application
IP (Ingress Protection Rating ) from IP20 to IP44 (IEC 60529)
Convection or forced air cooling
Double tube cooler
Leakage detector
Anti condensation heating
Temperature and pressure sensor
Pre magnetisation transformer
Current transformers
Over voltage protection
...
Apr-17

7. Requirements During Life Span 20+ years
Inrush current during switch on
Stress on insulation caused by switching surges and overvoltages
Load Shedding and Short Circuits
Harmonics
Load Cycles and Load Changes
Environmental Conditions at place of installation
Transport
Ventilation
Apr-17

8. Selection Criteria Max Loading Load Cycle Flux Density Cost of Energy
Environmental Conditions
Current Harmonics, Voltage Harmonics
Life-Cycle Cost – Investment
Apr-17

9. Cast Resin Transformers
Apr-17

10. SGB Cast Resin Transformer
Upper yoke
Bar cylinder
Connection of temperature sensors
Lifting lugs
Upper core clamp
Rollers
Lower core clamp
Core leg
Lower yoke
LV terminal
Coil support
HV terminal
HV winding
Delta connection
Carriage frame
Apr-17

11. Materials

12. Materials Materials used:
Insulated round or rectangular wire Transposed conductors
Glass fibre web (120 g/m²) as layer insulation
Textile glass mat for the layer insulation
Glass fiber tape for the edge strips
Epoxy resin
Apr-17

13. Core
Clamping bar
Coil Support
Bandage
Rubber
Apr-17

14. HIGH Voltage Winding

15. a.) Double-layer winding
SGB Cast Resin Transformer
Winding Technologies
High Voltage Winding
a.) Double-layer winding
SGB Principle
b.) Disk winding with wires
c.) Disk winding with foils
d.) Random distributed wire winding
a.)
b.)
c.)
d.)
Apr-17

16. SGB Cast Resin Transformer
Low voltage winding
Bar cylinder
Conductor
High voltage winding
Apr-17

17. SGB - Cast Resin Technology is superior
Surge - proof
HV SGB-double layer +
proprietary vacuum moulding =
less sensitivity
to impulse voltages caused by lightning strikes etc.
Apr-17

18. SGB - Cast Resin Technology glass fibre reinforced
SGB- technology
less sensitive to temperature shocks (due to the use of glass fibre reinforced epoxy system)
achieving double the tensile strengthts
of conventional cast resin systems
allowing for the manufacturing of copper and aluminum
Apr-17

19. Vacuum chamber for vacuum impregnation of high voltage winding
Winding completely encapsulated in resin void free casted under vacuum
Apr-17

20. Temperature expansion coefficients
Thermal reliability
Temperature expansion coefficients
Pure resin
63 x 10 –6
cm/°C
Quarz filled resin system
28 x 10-6
Aluminium
24 x 10-6
Resin glas fiber impregnated
20 x 10-6
Copper
17 x 10-6
SGB
Temperature expansion coefficients of glas fiber reinforced systems are close to copper and aluminium conductor
Apr-17

21. SGB - Cast Resin Technology
Cooling ducts in the HV-winding
SGB- double layer high voltage winding easily allows to implement cooling ducts for ideal temperature distribution and long life-time
No Cooling duct
1 Cooling duct = 1.9 x cooling surface!!
Apr-17

22. Low Voltage Winding

23. Winding principles Winding Technologies Low Voltage Winding a.) b.)
a.) flat wire (rectangular wire)
b.) continuous transposed wire
c.) non casted foil (resin encapsulated)
Apr-17

24. Prepreg (class F or H) Coated with non cured resin
Low voltage winding
Foil (Cu/Al)
Prepreg (class F or H) Coated with non cured resin
Edge strip
Apr-17

25. Low voltage winding
Outer connection bar
Cooling ducts
Apr-17

26. Routine tests at cast resin transformers
HV winding release test
Ratio, tappings, vector group
Winding resistance HV-/LV-winding
No load measurement P0, i0
Short circuit measurement, PK, UK , Ur , Ux
Separate source withstand voltage 50 Hz
Induced overvoltage test >/= 100 Hz
Partial discharge measurement
Apr-17

27. Short circuit withstand test
Type tests
Impulse test 1,2/50 µs
Temperature rise test
Short circuit withstand test
Noise level measurement (at no load)
Apr-17

28. Special tests (on request)
Climatic behaviour test
Environmental behaviour test (Salt spray test; Salt water submergion test)
Fire behaviour test
Test of impulse distribution
Switch overvoltage test
Flue gases emission test
Apr-17

29. Marine Applications

30. Projects – some examples
Apr-17

31. Projects – some examples 2
Apr-17

32. IP44 Forced air principle
Apr-17

33. IP44 Transformer system for propulsion drive
Connector box
Cooling unit :
Fans
2 tube system
Leakage detector
Apr-17

34. Vibration proof Ship transformer Splitted coils (Phase shift)
Additional mechanical stabilizer
Connection bars

35. Options on Marine housing
Thermal Sensor for hot air
Non return flap
Cooling unit
Thermal sensor cool air
Apr-17

36. Options on Marine housing
High pressure release
Thermal control
Heating element
Apr-17

37. Drive Applications
Apr-17

38. SGB transformers for drive applications
Transformers for Drives
6 – pulse
12 – pulse
18 – pulse
24 – pulse
30 – pulse
48 – pulse
Approvals
Acc to GL , LR, DNV, RINa, BV, ABS
ANSI / NEMA
EN50329
IEC 60146
GOST
References:
Propulsion TX for
Azimuth-, bow-, retractable thruster drive
Undergrounds Berlin, London, Prague, Washington, Atlanta ..
Light Rail System Dallas
Bay Area Rapid Transit SF
Apr-17

39. Failure on Marine Applications = 0 !
Reliability
Mean Time Between Failure
MTBF = Years !
Failure on Marine Applications = 0 !
Die MTBF wurde mit einer einfacher Formel ermittelt: Störgrößen wurden nicht mit berücksichtigt
1985 – 2010: Failure rate Cast Resin Tx manufactured ; 132 failures  0,40 %
Apr-17

40. Thank you