3,500 SGB-SMIT AT A GLANCE YEARS OF EXPERIENCE COUNTRIES EMPLOYEES READY FOR YOUR MARKET PRODUCTS
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1 TECHNICAL PROFILE
2 2 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS WHO WE ARE SGB-SMIT AT A GLANCE 450 YEARS OF EXPERIENCE Combined, more than Basis for know-how and for know-why More than 3,500 EMPLOYEES take care of your project In more than 80 COUNTRIES satisfied customers READY FOR YOUR MARKET PRODUCTS The SGB-SMIT Group manufactures transformers for applications worldwide. Sales and service centers on all continents ensure optimum processes. Our products meet the requirements in accordance with the applicable national standards. large power transformers medium power transformers large liquid-cooled distribution transformers liquid-cooled distribution transformers cast resin transformers shunt reactors series reactors phase shifters Lahmeyer-Compactstationen Transformers from 50 kva up to incl. 1,200 MVA in the voltage range up to 765 kv. QUALITY MANAGEMENT The SGB-SMIT Group is certified in accordance with: DIN ISO 9001 DIN ISO DIN ISO OHSAS TECHNOLOGIES Technologies for conventional and renewable energy. Status: December 2018
3 SGB-SMIT GROUP SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 3 SGB SMIT POWER MATLA A MEMBER OF THE SGB-SMIT GROUP SGB-SMIT POWER MATLA (previously known as Powertech Transformers) has over 70 years experience in successful design, manufacturing, testing, installation and commissioning of a full range of power and distribution transformers which include large power transformers of voltages up to 800MVA. SGB-SMIT POWER MATLA CUSTOM DESIGNED SGB-SMIT POWER MATLA (Pty) Ltd (formerly known as Powertech Transformers) is owned by SGB-SMIT (GmbH) and Power Matla. SGB-SMIT, is the largest independent and pure-play transformer manufacturer in the world, with headquarters in Regensburg, Germany. They are represented on 5 continents in 8 countries with plants in Germany, the Netherlands, USA, Romania, Malaysia, India, China and the Czech Republic. With transformer expertise since 1913 they produce transformers ranging from 50 kva up to 1,200 MVA. Power Matla (Pty) Ltd is a locally owned black empowered company with investments in various portfolios within the renewable energy, ICT, mining and power utilities markets providing good shareholder value and solid returns. The company consists of Large Power Transformers manufacturing plant in Pretoria and Distribution Transformers plant in Cape Town and supplies a full range of transformers, from generator step-up to transmission and distribution transformers. The range includes three-phase and singlephase units, auto-transformers, arc-furnace, locomotive and traction transformers, miniature sub-stations, NECRT s as well as shunt reactors. Every SGB-SMIT POWER MATLA unit is custom-made from standardised design elements and using uniform manufacturing operations. This flexible, but well co-ordinated approach ensures the highest quality of design and construction for all our transformers and makes the best possible use of the valuable knowledge and experience gained over the years and best practices developed in our factory. The large power transformer factory in Pretoria is a wellequipped factory and is amongst the biggest and most sophisticated transformer manufacturing plants within the Southern Hemisphere and one of two large transformer manufacturers within sub-saharan Africa. The distribution transformers factory in Cape Town has been manufacturing distribution transformers and miniature substations for more than 60 years.
4 4 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS CUSTOMERS SMALL, MEDIUM AND LARGE POWER TRANSFORMERS ALL OVER THE WORLD 1 Shipping 2 Oil & Gas Solar Power Stations Power Plants Onshore Offshore Power Distribution Railway Industry High Buildings / Data Center Hydro Power EXPERIENCE AND DESIGN CAPABILITY SGB-SMIT POWER MATLA have many years of experience in the design, manufacturing, installation and commissioning of small, medium and large power transformers for various applications. Our design experience range from small power transformers (SPT < 60MVA, < 132kV) up to large power transformers (LPT 800MVA, 500kV) including Generation Step-up Units (GSU s). In addition, all aspects of auxiliary control circuit application and layout designs are also provided. DESIGNS The transformers manufactured by SGB-SMIT POWER MATLA range from standard designs in accordance with IEC requirements to complex designs specific for a customer s individual requirements in all applications and industries across the African continent and overseas. The software available to our designers is a state of the art integrated design system. This includes winding design and optimisation; graphical electromagnetic field line plots by means of 3D Finite Element Method modelling; temperature analysis; short circuit stress calculations to full 3D CAD modelling of the transformer and its components. This allows our designers to customise each power transformer to specific customer requirements.
5 DESIGN SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 5 QUALITY, HEALTH, SAFETY & ENVIRONMENT DESIGN REVIEWS The power transformer plant located in Pretoria (Gauteng) is a world class manufacturing facility and boasts a fully certified ISO 9001 quality management system, ISO environmental management system as well as the OHSAS health and safety management system. At every stage during manufacturing, the materials and processes are inspected by suitably qualified and experienced inspectors to ensure all required standards and manufacturing practices are adhered to. Six-sigma systems are built into every manufacturing process in the factory to enhance the quality and documentation of our products. Customer drawings are prepared for tender designs and finalised on order placement. All electrical and mechanical designs undergo an internal design review process. External design reviews by customers are also allowed for in the design process. If a detailed customer specification is not available, SGB-SMIT POWER MATLA can offer a cost effective design based on the requirements of IEC product standards. SGB-SMIT POWER MATLA can also provide template technical schedules based on the IEC requirements, should these not be available from the customer.
6 6 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS SUPPLY CHAIN TRANSFORMERS MADE BY SGB-SMIT POWER MATLA - STANDARD FEATURES SUPPLY CHAIN CORE DESIGN SGB-SMIT POWER MATLA prides itself in our ability to leverage our global network. We also manufacture most of the transformer structural components in-house. Raw materials and components not manufactured in-house are sourced from world class suppliers. Procurement of material and components is done from a list of pre-qualified suppliers locally and internationally who are certified to conform with the highest standards in terms of Quality (ISO9001), Health and Safety (OHSAS 18000) as well as Environmental (ISO 14000) respectively. Before a supplier is approved, their capability is assessed, by taking into consideration their technical ability; quality control system; safety, health & environmental controls; financial viability as well as other commercial factors. Supply level agreements are put in place with key suppliers to ensure availability of stock and continuity of supply. A number of enterprise development initiatives are considered for development of small independent business units. Core design principles are based on achieving the smallest active part possible whilst achieving low noise level, low no-load losses and ensuring high short circuit withstand capability of the overall core structure. The basic core design is either a threelimb or a five-limb type core. The core is composed of a circular cross-section without any bolts through the core. The joints are mitred and step-lap stacked. Selection of core steel material for a particular core ranges from conventional grain orientated electrical steel (GOES); to domain refined grain orientated electrical steel based on customer specifications for no-load losses and noise levels. Transport restrictions on weight and dimensions may influence the most appropriate core geometry for the transformer that is economical on losses; flux density; overall core weight and sound level. SGB-SMIT POWER MATLA applies strict control of incoming raw material from pre-qualified suppliers. All incoming goods are quality-controlled and checked before they are released into the sub-assembly manufacturing lines. Where certification is required, the raw material is sent to our on-site SANAS accredited laboratory for material analysis, verification and certification. Any non-conforming product is rejected and returned to the supplier for rectification or replacement.
7 WINDING DESIGN SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 7 WINDING DESIGN WINDING MANUFACTURE The transformer windings must have the ability to withstand high mechanical and electrical stresses resulting from short circuit conditions, lightning and switching surges as well as normal overload requirements during peak hours in daily operation throughout the lifetime of the transformer. Windings manufactured by SGB-SMIT POWER MATLA are made of annealed copper and guarantee high mechanical; electrical; and thermal stability under abnormal conditions. This ensures the safe operation of the transformer over it s lifetime. Winding technologies are layer, helical, continuous disk and interleaved disk depending on the operating conditions as determined by the rated apparent power; rated voltage; network fault level as well as the climatic conditions of the site of operation and specified temperature rise limits. Disk windings are suitable for higher voltages while layer and helical windings are suitable for lower voltages. The conductor used on windings is oxygen free copper. The shape of the conductors is rectangular with small edge-radii. The conductor is often divided into two or more parallel strands to reduce the eddy current losses within the winding. transformer with regard to the electrical and mechanical requirements. Each strand is insulated either by thermally upgraded paper covering, or by an enamel coating, or both. Two separately insulated and parallel strands may sometimes have a common paper covering. Conductor types can be strip conductor or CTC (Continuously Transposed Conductor). Manufacturing of windings is carried out by suitably qualified and experienced winders on vertical or horizontal winding machines. Winding machines are precisely controlled to achieve constant contact pressure and winding tension.
8 8 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS WINDING MANUFACTURE INSULATION MATERIAL INSULATION OIL Material for the insulation structure and barrier boards is manufactured from high quality compressed transformer board, compacted laminated wood and/or fibre sheets depending on the application within thetransformer with regard to the electrical and mechanical requirements. The mineral oil inside the transformer tank acts as an insulation medium as well as a coolant for the windings inside the transformer. The mineral oil used in our transformers complies with international standards. Only virgin oil is used (free of contaminates) and no recycled oil is used to fill the transformers. Elevated temperatures (hot-spots) in transformers are detrimental to paper insulation s longevity due to the decomposition of the cellulose bonding inside the paper. This results in the degradation of the insulation between strands which may lead to premature insulation failure of the transformer. For paper insulated conductor used on windings, SGB-SMIT POWER MATLA has standardised on thermally upgraded paper for all windings types. This ensures an additional 10Kelvin hot spot temperature margin resulting in an extended life of the transformer.
9 TANK MANUFACTURE SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 9 TANK DESIGN TANK MANUFACTURE The transformer tank accommodates the core and windings (active part) as well as insulating oil. It serves as a support structure for accessories and control equipment as well as acting as physical protection for the active part. Due to its vital role the tank design must be robust and very reliable implying the use of high quality material. The transformer tank is usually of the rigid type with removable radiators connected by shut-off valves. The tank shape and size is designed to optimise the quantity of material used taking into consideration the electrical clearance requirements, structural strength and required oil volume. The base is flat with a minimum thickness of 20mm and is determined by the lifting capacity required for the core and winding masses. Mild steel plates are the main building material used in our tank, cover and conservator as well as all the pipes and fittings. However, where there is a serious concern with high temperatures caused by eddy losses around high current carrying bushings in which case stainless steel is used instead. Double welding is used where oil tightness is required. Rubber or cork rubber compound is used for the gaskets on flanged connected pipe joints/transport and inspection cover openings and all other valves and fittings.
10 10 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS PAINTING & SURFACE TREATMENT PAINTING AND SURFACE TREATMENT SGB-SMIT POWER MATLA has a range of proven surface treatments depending on the transformer site climatic conditions and application environment. All paint and coatings are done in accordance with a documented in-house painting system complying with strict safety, health, environmental and quality requirements. All new transformers, irrespective of whether they are operating in non-corrosive or corrosive environments, are coated in accordance with SGB-SMIT POWER MATLA s corrosive protection specification. External tank surfaces are painted with a two-component epoxy primer followed by a twocomponent acrylic or polyurethane finishing coat. MAIN TERMINALS Customers have a choice of bushings from standard solid porcelain oil impregnated (OIP) type bushings to resin impregnated (RIP) bushings for various applications such as Oil-to-Air, Oil-to-Oil, Oil-to-SF6, Air-to-Air and Air-to-SF6. Our bushings are always sourced from world class suppliers of bushings, who comply with international standards and are generally positioned on the cover. For voltages above 52 kv, condenser type bushings which facilitate the electric stress control via the insertion of floating aluminium equaliser screens which are located in the condenser core are used. Enclosures can be provided on the primary and/or on the secondary side and may be constructed for cable or bus duct connection. Transformers may also be provided with plugin or cable box bushings. Separate radiators are generally hot-dip galvanised. Moreover, test standards include partial discharge measurements at a max. basic interference level of approx pc, allowing significant improvement on the value specified by the applicable standards. In addition to the standard corrosion protection painting system, a zinc-metal spray coating can be applied on customer request. Other customer specific painting system requirements are also provided for. All external surfaces of the transformer and accessories are colour coded in accordance with the Natural Colour System (NCS codes) or RAL international colour standards to a customer s unique requirements.
11 ACCESSORIES SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 11 ACCESSORIES Depending on the type and application of the transformer the accessories will usually include a combination of the following items either as standard or optional as per customer requirements: Bushings (Oil or Resin Impregnated, Oil-to-Air, Oil-to-Oil; Oilto-SF6) Oil conservator with level indicator Rubber-bag with bag leak detector in the conservator to prevent oil coming into direct contact with air Tap changers (oil type as well as vacuum) Filling and drain valves Oil sampling device Earthing terminals Lifting lugs Jacking pads Radiator panels Silica-gel breather Buchholz relay (GOR) Winding Temperature Indicators and Oil Temperature Indicators (Analogue or Digital). Fibre optic probes for direct hot spot temperature measurements on active part. Pressure relief devices and provision for pressure purging systems. Provision for water cooled systems Impact recorders Separate core and core clamp earth test positions Other additional accessories can be fitted according to customer specifications. DRYING AND VACUUM TREATMENT The moisture content in oil and solid insulation can have adverse effects on the life span of the transformer since it affects the dielectric breakdown strength of solid and liquid insulation. This affects the rate at which the cellulose ages and the propensity for bubble evolution during overloads. In order to counteract these negative effects of moisture adequate drying and vacuum treatment is performed using proven technology such as Vapour Phase Drying and Low Frequency Heating (LFH). Before filling, the oil is always degassed and purified. TESTING Every SGB-SMIT POWER MATLA transformer is individually tested according to major international standards as well as, in accordance with any special tests required by the customer, and must pass all these tests before leaving the factory. The test certificate forms part of the transformer operating manual. SFRA SFRA (Swept Frequency Response Analysis) fingerprinting is also done before the transformer leaves the factory and redone on site. Impact recorders are installed on the core as well as on the tank of the transformer to verify adverse impacts or accelerations in all three dimensions. Results of the SFRA test and impact recorder data are made available to our customers.
12 12 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS SMALL POWER TRANSFORMERS STANDARD AND COMPLEX SMALL AND MEDIUM POWER TRANSFORMERS SMALL POWER (SPT S) MEDIUM POWER (MPT S) SGB-SMIT POWER MATLA designs and manufactures small power transformers (SPT) ranging from 20 MVA to 63 MVA and up to 172 kv. The SPT range covers standard or complex applications from the typical substations to furnaces, tractions, rectifiers and reactors. We have the skills and resources to deal with specific customer needs in terms of engineering or assembly requirements, special accessories as well as special materials or components. The following transformers are included in the SPT range: Double Wound or Auto-Connected Outdoor bushings or cable box applications 3 phase with/without OLTC 2 windings with/without OLTC and with/without stabilising winding. ONAN/ONAF/OFAF/ODAF cooling Standard/High impedance Low sound pressure level SGB-SMIT POWER MATLA designs and manufactures medium power transformers (MPT) ranging up to 200 MVA 275 kv. Other power transformer sizes in the MPT range are rated above 200 MVA up to 72 kv. The MPT range covers mostly customer applications such as GSU and system power transformers. We have the skills and resources to deal with customer needs, however complex these may be in terms of engineering or assembly requirements; special accessories and special materials or components. The following transformers are included in the MPT range: 3 phase with/without OLTC/OLTS/Link Board 2 windings with/without OLTC/OLTS/Link board and with/ without (not loaded) stabilising winding ONAN/ONAF/OFAF/ODAF cooling Standard/High impedances Low sound pressure level
13 INSTALLATION & SERVICE SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 13 LARGE POWER (LPT S) SGB-SMIT POWER MATLA designs and manufactures large power transformers (LPT) with a three phase power rating higher than 200 MVA or with voltage ratings higher than 275 kv. We supply three phase units up to 800 MVA and single phase units up to 500 MVA. LPT s are mostly commonly used in customer applications such as GSU transformers, system power transformers and large transmission transformers. The following transformers are included in the LPT range: 3 phase with/without OLTC/OLTS/Link Board 2 windings with/without OLTC/OLTS/Link board and with/ without (not loaded) stabilising winding ONAN/ONAF/OFAF/ODAF cooling Standard/High impedances Low sound pressure level
14 14 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS TECHNICAL DATA SHEETS TRANSFORMER RANGE DEFINITION System Voltage kv LPT > 275 kv 275 kv MPT > 200 MVA 172 < kv < 275kV (or BIL > 650kV) 172 kv For SPT 1-5 max BIL 650 kv SPT 1-2 < 40 MVA 72.5 < kv < 171 Max BIL 650 kv SPT < MVA < 63 > kv Max BIL 650 kv MPT > 63 < MVA & < < kv < 172 LPT > 200 MVA & > 72,5 kv 72.5kV LDT < 40 MVA < 72.5 kv LDT 40 < MVA < 63 < 72.5 kv MPT > 63 MVA & < 72,5 kv 40MVA 63MVA 200MVA MVA
15 TECHNICAL DATA SHEETS SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 15 TRANSFORMER RANGE DEFINITION
16 16 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS TECHNICAL DATA SHEETS SPT TECHNICAL DATA SHEET Nominal Voltage Overall dimensions Transformer Mass (kv rms) Rating of Imped (m) (Ton) MVA Vector Prim Sec Te r (MVA) Tap(%) Group A B C D E F With Oi l Without Oi l YNa0d1 mi n ma x YNa0d1 mi n ma x YNa0d1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNa0d1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YHd1 mi n ma x YNd1 mi n ma x YNad1 mi n ma x YNa0d1 mi n ma x YNa0d1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNa0d1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x YNd1 mi n ma x Notes: Dimensions and masses in the above table are from typical designs completed in recent years and may vary from these values. Specific values might change based on specific customer requirements. Contact SGB-SMIT POWER MATLA to verify dimensions for specific applications. Designs and sizes are not limited to the transformer sizes listed in the table above.
17 TECHNICAL DATA SHEETS SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 17 MPT TECHNICAL DATA SHEET Nominal Voltage Overall dimensions Transformer Mass (kv rms) Rating of Imped (m) (Ton) MVA Vector Prim Sec Te r (MVA) Tap(%) Group A B C D E F With Oi l Without Oi l Various YNa0d1 mi n ma x YNa0d1 mi n ma x Various YNa0d1 mi n ma x Various YNa0d1 mi n ma x to YNa0d1 mi n ma x YNa0d1 mi n ma x YNd1 mi n ma x Various YNa0d1 mi n ma x YNd1 mi n ma x YNa0d1 mi n ma x Various YNa0d1 mi n ma x YNa0d1 mi n v Various YNaod1 mi n ma x Various YNaod1 mi n ma x to YNa0d1 mi n ma x Notes: Dimensions and masses in the above table are from typical designs completed in recent years and may vary from these values. Specific values might change based on specific customer requirements. Contact SGB-SMIT POWER MATLA to verify dimensions for specific applications. Designs and sizes are not limited to the transformer sizes listed in the table above.
18 18 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS TECHNICAL DATA SHEETS LPT TECHNICAL DATA SHEET Nominal Voltage Overall dimensions Transformer Mass (kv rms) Rating of Imped (m) (Ton) MVA Vector Prim Sec Te r (MVA) Tap(%) Group A B C D E F With Oi l Without Oi l YNa0d1 mi n ma x Various YNa0d1 mi n ma x YNa0d1 mi n ma x Various YNd1 mi n ma x Various YNd1 mi n ma x YNa0d1 mi n ma x Various YNa0d1 mi n ma x Various YNd1 mi n ma x YNa0d1 mi n ma x Various YNd1 mi n ma x YNa0d1 mi n ma x Various YNd1 mi n ma x Various YNd1 mi n ma x YNa0d1 mi n ma x YNa0d1 mi n ma x Various YNa0d1 mi n ma x YNa0d1 mi n ma x Various YNa0d1 mi n ma x YNa0d1 mi n ma x Various YNd1 mi n ma x Various YNd1 mi n ma x Notes: Dimensions and masses in the above table are from typical designs completed in recent years and may vary from these values. Specific values might change based on specific customer requirements. Contact SGB-SMIT POWER MATLA to verify dimensions for specific applications. Designs and sizes are not limited to the transformer sizes listed in the table above.
19 SMALL, MEDIUM AND LARGE POWER TRANSFORMERS 19
20 CONTACT STARKSTROM-GERÄTEBAU GMBH Regensburg Germany Phone SMIT TRANSFORMER SALES INC. Summerville, SC USA Phone COPYRIGHT 2019 Subject to technical changes. SÄCHSISCH-BAYERISCHE STARKSTROM-GERÄTEBAU GMBH Neumark Germany Phone ROYAL SMIT TRANSFORMERS B.V. Nijmegen The Netherlands Phone SMIT TRANSFORMER SERVICE Nijmegen The Netherlands Phone RETRASIB S.A. Sibiu Romania Phone SGB CZECH TRAFO S.R.O. Olomouc Czech Republic Phone BCV TECHNOLOGIES Fontenay-le-Comte France Phone SGB-USA INC. Louisville, OH USA Phone OTC SERVICES INC. Louisville, OH USA Phone SGB MY SDN. BHD. Nilai Malaysia Phone SGB TRANSFORMERS INDIA PVT. LTD. Chennai India Phone SGB CHINA Yancheng P.R. China Phone SGB-SMIT POWER MATLA Pretoria West South Africa Phone Cape Town South Africa Phone SGB-SMIT POWER MATLA 1 Buitenkant Street. Pretoria West 8 Eliot Avenue, Epping 2, Cape Town Phone Fax info@sgbsmitpowermatla.com
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