One of the leading manufacturersOne of the leading manufacturers

for transformers worldwidefor transformers worldwide

Apr-13

Chart 0

SGB at a glanceSGB at a glance

SGB Regensburg

SBG Neumark

SGB USA Inc. AM SGB SMIT 

50 kVA up to 1.200 MVAturnover (2010):  ~ EUR 580 million1.309 employeesHeadquarters: Regensburg, Germany5 production plants worldwide

SGB-CR

STS

SGB-USA

SGBSGB--SMIT Group: SMIT Group: steadily growing experticesteadily growing expertice

1993 1994 2000 20101947 1990

SBG

Fo

rmat

ion

AM

SG

B

Form

atio

n

SGB

Fo

rmat

ion

TRR

A

cqui

sitio

n

SMIT

A

cqui

sitio

n

580 Mio €

0,65 Mio €

Umsatz

SGB

TRR

SBG

AM SGB

SMIT

SGB – SMIT Gruppe

Employees,incl. trainees 31.12.2010: 1.390

2009

SGB

-CR

Fo

rmat

ion

STS

Form

atio

n

2010

SGB

-USA

Fo

rmat

ion

2008

Apr-13

Chart 1

Apr-13

Chart 2

SGB global presence SGB global presence cast coil transformerscast coil transformers

DTPL, India

SGBXintai

SGB Locations SGB Locations in Europe, North America and Asia.in Europe, North America and Asia.

SGB USA Inc.

Nilai

SGBMedium Power(for substations)

Power PlantsPower Plants High VoltageHigh Voltage Medium VoltageMedium Voltage Low VoltageLow Voltage

SGB / AMSGBCast Resin

(for industry,wind power, marine appl.)

SBG / AMSGBOil-Distribution

(for local grids; transformer stations)

220 kV220 kV 110 kV110 kV 30/20/10 kV30/20/10 kV 400/240 V400/240 V220-550 kV220-550 kV

10 – 150 MVA10 – 150 MVA 50 KVA – 30 MVA50 KVA – 30 MVA150 – 1.200 MVA150 – 1.200 MVA

Energy Companies

Transformer

Voltage /Capacity

Customers Energy Companies Energy Companies, Grid Companies, IndustryEnergy Companies, Grid Companies, Industry

Industry, Local Energy Supplier,

Marine application

Industry, Local Energy Supplier,

Marine application

Industry, Local Energy Supplier, Public Utilities

Industry, Local Energy Supplier, Public Utilities

The group covers the complete transformer programme.

SMITLarge Power

(for power plants and substations)

Apr-13

Chart 3

Range of ApplicationRange of Application

Apr-13

Chart 4

SGB RegensburgSGB Regensburg

Service voltage up to incl. 36 kV

BIL up to incl. 200 kV

Rated power 50 kVA – 30 MVA

2- and 3-winding transformers

acc. to VDE 0532 / IEC 726

Special transformers:Rectifier transformersReactancesothers

Cast Resin Transformers

Types

Apr-13

Chart 5

SGB RegensburgSGB Regensburg

Public Utilities

Large industrial energy usersAutomobile industryChemical industry

Regional and national transport systems

Internet Centers

Plant contractorsIndustrial plantsPower supply networks and substations

Wind power facilities (on-/offshore)

Marine applications

Markets for Cast Resin Transformers

Apr-13

Chart 6

SGB transformers for SGB transformers for ships and oil rigsships 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

...

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

VentilationApr-13

Chart 7

Requirements During Life Span 20+ yearsRequirements During Life Span 20+ years

Max Loading

Load Cycle

Flux Density

Cost of Energy

Environmental Conditions

Current Harmonics, Voltage Harmonics

Life-Cycle Cost – Investment

Apr-13

Chart 8

Selection CriteriaSelection Criteria

Apr-13

Chart 9

Cast Resin

Transformers

Upper yokeBar cylinder

Connection of temperature sensors

Lifting lugsUpper core

clamp

Rollers

Lower core clamp

Core leg

Lower yoke

Apr-13

Chart 10

SGB Cast Resin TransformerSGB Cast Resin Transformer

Coil support

HV terminal

HV winding

Delta connection

LV terminal

Carriage frame

Materials

10.04.2013

11

Apr-13

chart 12

MaterialsMaterials

Materials used:

Insulated round or rectangular wireTransposed 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-13

Chart 13

CoreCore

Clamping bar

Bandage

Coil Support

Rubber

HIGH Voltage Winding

10.04.2013

14

Apr-13

chart 15

a.) Double-layer winding

a.) b.) c.) d.)

b.) Disk winding with wires

c.) Disk winding with foils

d.) Random distributed wire winding

SGB Principle

SGB Cast Resin TransformerSGB Cast Resin Transformer

Winding TechnologiesHigh Voltage Winding

Apr-13

Chart 16

SGB Cast Resin TransformerSGB Cast Resin Transformer

Low voltage windingBar cylinder

Conductor

High voltage winding

Apr-13

Chart 17

SGB SGB -- Cast Resin Technology is superiorCast Resin Technology is superior

HV SGB-double layer +

proprietary vacuum moulding=

less sensitivity to impulse voltages

caused by lightning strikes etc.

Surge Surge -- proofproof

Apr-13

Chart 18

SGB SGB -- Cast Resin Technology glass fibre reinforcedCast 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-13

chart 19

Vacuum chamber for vacuum Vacuum chamber for vacuum impregnation of high voltage windingimpregnation of high voltage winding

Winding completelyencapsulated in resin

void free casted under vacuum

Apr-13

chart 20

Thermal reliabilityThermal reliability

Pure resin 63 x 10 –6 cm/°C

Quarz filled resin system

28 x 10-6 cm/°C

Aluminium 24 x 10-6 cm/°C

Resin glas fiberimpregnated

20 x 10-6 cm/°C

Copper 17 x 10-6 cm/°C

Temperature expansion coefficients

Temperature expansion coefficients of glas fiber reinforced systems are close to copper and aluminium conductor

SGB

Apr-13

Chart 21

SGB SGB -- Cast Resin TechnologyCast Resin Technology

SGB- double layer high voltage winding easily allows to implement cooling ducts for ideal temperature distribution and long life-time

Cooling ducts in the Cooling ducts in the HVHV--windingwinding

No Cooling duct 1 Cooling duct = 1.9 x cooling

surface!!

Low Voltage Winding

10.04.2013

22

Apr-13

chart 23

Winding principlesWinding principles

a.) b.) c.)

c.) non casted foil (resin encapsulated)

a.) flat wire (rectangular wire)

b.) continuous transposed wire

Winding TechnologiesLow Voltage Winding

Apr-13

Chart 24

Low voltage windingLow voltage winding

Edge strip

Foil (Cu/Al)

Prepreg (class F or H)Coated with non cured resin

Apr-13

chart 25

Low voltage windingLow voltage winding

Cooling ducts

Outer connection bar

Apr-13

chart 26

Routine tests at cast resin transformersRoutine 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-13

chart 27

Type testsType tests

Impulse test 1,2/50 µs

Temperature rise test

Short circuit withstand test

Noise level measurement (at no load)

Apr-13

chart 28

Special tests (on request)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

Marine Applications

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29

Apr-13

Chart 30

Projects Projects –– some examplessome examples

Project QtyRating (kVA)

Voltage Prim/Sec

Cooling / IP 

Mariotti " MAR062 / 063 / 064 " 8 5400/2700/2700 6600/1330/1330 AF / IP44

4 5400/2700/2700 6600/1330/1330 AF / IP44

6 4500 6600/440 AF / IP44

3 1000/250/750 6600/440/230 AN / IP23

Cruise Liner 6223 / 622 12 3150 11000 / 735 AF / IP44

17 2350 / 750 / 1600 11000 / 245 / 735 AN / IP00

4 2200 / 600 / 1600 11000 / 233 / 466 AN / IP00

Ice Explorer 2 2400 690 / 742 AN / IP00

Mitsubishi Hull 2180 2 6550 11000/1500 AF / IP44

2 6550 11000/1500 AF / IP44

2 6550 11000/1500 AF / IP44

2 6550 11000/1500 AF / IP44

2 4800 11000/470 AF / IP44

2 2600 11000/470 AF / IP44

4 2250 11000/470 AN / IP00

6 1800 11000/470 AN / IP00

Solitaire Rohrleger 4 3000/1500/1500 10000/800/800 AN / IP23

Taiyo 4 4000 600/6000 AN / IP23

SAM "Hopperbagger" 1 1800 6600/690 AN / IP23

1 4300 6000/690 AF / IP44

1 2400 6000/690 AN / IP23

1 1300 6000/660 AN / IP23

Apr-13

Chart 31

Projects Projects –– some examples 2some examples 2

Project QtyRating (kVA)

Voltage  Prim/Sec

Cool ing / IP 

Pride of America 2 3500 11000/460 AF / IP442 2100 11000/460 AF / IP444 1500 11000/460 AN / IP235 2100 11000/460 AN / IP23

P&0 "Aurora" 8 8400 6600 / 2000 AF / IP442 1500 6600 / 450 AN / IP002 1500 6600 / 630 / 450 AN / IP004 1000 6600 / 690 / 400 AN / IP004 630 6600 / 400 AN / IP004 1800 6600 / 690 AN / IP001 4500 6600/440 AF / IP44

"Costa Olympia" STN 8 9700 10000 / 1510 AF / IP44"Costa Victoria" STN 4 2400 10000 / 450 AN / IP23

4 900 10000 / 450 AN / IP234 1350 10000 / 450 AN / IP234 1150 / 650 / 550 10000 / 450 / 230 AN / IP234 1250 / 650 / 550 10000 / 450 / 230 AN / IP234 1600 / 950 / 500 10000 / 450 / 230 AN / IP234 1350 / 600 / 850 10000 / 450 / 230 AN / IP234 1350 / 950 / 500 10000 / 450 / 230 AN / IP238 25 2031 / 440 AF / IP44

Apr-13

Chart 32

IP44 Forced air principleIP44 Forced air principle

Apr-13

Chart 33

IP44 Transformer system for propulsion IP44 Transformer system for propulsion drivedrive

Connector box

Cooling unit :• Fans

• 2 tube system• Leakage detector

10.04.2013

34

Vibration proofVibration proof

Ship transformer

• Splitted coils (Phase shift)• Additional mechanical stabilizer• Connection bars

Apr-13

Chart 35

Options on Marine housingOptions on Marine housing

Thermal Sensor for hot air

Non return flap

Thermal sensor cool airCooling unit

Apr-13

Chart 36

Options on Marine housingOptions on Marine housing

High pressure release

Thermal control

Heating element

Apr-13

Chart 37

Drive Applications

Apr-13

38

SGB transformers for drive SGB transformers for drive applicationsapplications

References:Propulsion TX for

Azimuth-, bow-, retractable thruster drive

UndergroundsBerlin, London, Prague, Washington, Atlanta ..

• Light Rail System Dallas• Bay Area Rapid Transit SF

Transformers for Drives6 – pulse

12 – pulse

18 – pulse

24 – pulse

30 – pulse

48 – pulse

ApprovalsAcc to

GL , LR, DNV, RINa, BV, ABS

ANSI / NEMA

EN50329

IEC 60146

GOST

Apr-13

Chart 39

ReliabilityReliability

0

500

1000

1500

2000

2500

0

10

20

30

40

50

60

70

80

90

100

1985 87 89 91 93 95 97 99 01 03 05 07 09

Nos

. sup

plie

d

Nos

. fai

lure

Year

MTBF = 2412 Years !

Mean Time Between Failure

1985 – 2010: Failure rate33249 Cast Resin Tx manufactured ; 132 failures ≈ 0,40 %

Failure on Marine Applications = 0 !Failure on Marine Applications = 0 !

10.04.2013

40

Thank you

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