Prime Power Energie Systems Inc. C a s t C o i l Tr a n s f o r m e r s 100 kva to 30 MVA 2 3kV tto 34 2.3kV 34.5kV 5kV Extraordinary Quality, Reliability and Service Energy Efficient Low Total Owning Cost Proven World Class Leader
World Class Cast Coil Transformers with Credentials This brochure is an overview of why JST can qualify as your prime source for Cast Coil Transformers. JST has served the North American market since 1998 and brings extensive experience of over 25 years serving other major world markets. Over this period, we have demonstrated t d areliability and service record of the highest level globally. This is the core of JST s credentials. We welcome the inspection of our claims and comparison against any other sources. We appreciate and value the opportunity to discuss your needs and any other questions you may have about JST Cast Coil transformers. Credentials Related Comments Ref. Pages Experience record -Over 20,000 000 MVA installed in a diverse range of duty and in the most demanding 2 applications and environments St andards and Designs -Meets All US or IEC Standards -Proven May Christie technology -Ratings through 15,000 kva and 34.5kV -185 / 115 and 80 rise; and 150 / 80 rise 3 Product Performance -Meets or exceeds all standard and customer specifications 3,4 Reliability -A reliability record superior on a global comparison (99.9%) Performance Design and -State of the Art, automated, design (CAD), core, coil, casting manufacturing and 5, 6, 7, 8 Manufacturing testing systems. Systems and Facilities - Clean, orderly facilities, precise and consistent, cost effective Quality Systems -Philosophy Highest possible quality standards followed throughout all operations Tests and Certification -All C57.12.91 tests plus many optional tests -Certification: ISO9001, ISO14001, KEMA UL & cul listed 4,8 Fit-Finish and Features - Superior by design and it shows 9 Order/ Customer -95% of quotes within 2 days 10,11 Service Product Service -Competitive US factory and field service Delivery Service -Competitive lead times -99% on-time delivery record Total Owning Cost Lowest Total Owning Cost Efficiency i + all other costs 11 (TOC) All add up to superior performance, and a high confidence level, critical in reliable application of Cast Coil Transformers.
JST Served Market Experience JST Cast Coil Transformers offer the ultimate in performance and reliability while serving the most severe and demanding applications and environments environments. Solid cast resin construction of primary and secondary coils have demonstrated superior capability and exceptional reliability. Low installation cost no need for liquid containment Withstand extreme impact and short circuit loads Impervious to Moisture, contaminants and other hostile environments Exceptionally long life with minimal maintenance Windpower Airports Trains and Subways Universities Cast Coil Transformer Computer Data Centers Hospitals Power Systems Office Buildings
Standard and Optional Ratings and Features Sizes Available kva 150, 300, 500, 750, 1000, 1250, 1500, 2000, 2500, 3000, 3250, 3750, 5000, 7500, 10000, 12000, 15000, 20000 Primary Voltage Classes, kv 2.3, 5, 8.7, 15, 25, 34.5 Secondary Voltage, kv 0.208, 0.24, 0.48, 2.4, 4.16, 6.9, 12.47, 13.2, 13.8 Basic Impulse Levels, kv Standard Optional 1.2 10 20,30 2.5 30 45 5.0 60 75 8.7 75 95 15 95 110 25 125 150 34.5 150 170 Winding Temperature Rise, o C 80 115 Impedance 5.5% through 7.5% depending on HV, HV and LV ratings Forced Air Rating 133% 140% 300-15,000kVA Conductor Material Copper Aluminum Ambient Operating Range, o C -40 to 30 avg/40 max to 50 Standard Features Windings Cast in vacuum in a mold Copper windings Step-lap mitered/cruciform core 185 insulation system 115 rise Four full capacity tap on HV winding rated 2 1/2%, 2-FCAN - FCBN on units with voltage above 601V NEMA 1 heavy-gauge ventilated enclosure with removable panels front and rear Provisions for lifting core and coil Vibration isolation pads between core and coil and enclosure Base equipped with Jack pads and designed for rolling or skidding in any direction Diagrammatic aluminum nameplate Partial discharge free (< 10 pc@120% rated voltage) Options Aluminum windings 80 average temperature rise NEMA 3R, NEMA 4, stainless steel enclosure Forced air cooling Three phase electronic temperature monitor Higher BIL Loss optimized designs (TOC) Humidity control / Heaters R-C Snubber Triplex Design Standard Certification UL 1562 ANSI C57.12.01, C57.12.91 ANSI ANSI N45.2-1977 NRC 10CFR50 Appendix B ISO9001 NEMA std20 CSA Z 299.3
Quality and Reliability Assurance Superior JST Cast Coil quality and reliability is the result of many key ingredients. Corporate Foundation Standards & Practices JST s foundation is built on the fundamental philosophy that customer satisfaction and long-term success depends on consistently supplying transformers on-time and of the highest possible quality, and that will perform well and reliably in the most severe applications and environments. Quality standards and practices per ISO 9001 are clearly documented, communicated and rigorously followed throughout all aspects of the business. Certifications ISO9001 ISO14001 OHSAS18001 KEMA UL Computer Aided Design The most advanced computer aided design (CAD) systems are operated by highly trained engineers, assuring accurate, optimized designs, exact fit of all parts, plus providing programs for automated core cutting and stacking, coil winding and testing. Highest Quality Materials All materials meet the highest standards with assurance per ISO 9001 -Core steel of high efficiency, high permeability grain oriented silicon steel -Insulation materials are used to meet UL certification State-of-the-Art Manufacturing Automated, state-of-the-art manufacturing systems are used in all stages of production core cutting and stacking, coil winding and casting, assuring precise, consistent transformers, with high efficiency, i low losses and noise Testing Each transformer is 100% tested to assure compliance with all customer specifications and to all US Standards per ANSI C57.12.91, and in accordance with ISO 9001 procedures. Routine Tests 1. Polarity and phase-relation tests 2. Ratio test 3. Winding resistance measurements 4. Separate-source AC withstand voltage test 5. Induced AC withstand voltage test 6. No-load loss and excitation current 7. Load loss and impedance 8. Partial discharge measurements 9. Insulation resistance measurements 10. Auxiliary control circuitry test Optional Tests Temperature Rise ANSI Impulse Sound Level Design Type Tests Short Circuit Seismic Qualifications
Core Manufacturing Process State-of-the-art manufacturing systems are used throughout JST s JST s entire operations. First is a detailed computer aided design defining the entire transformer and all of its components in exact detail. GEORG automated cutting and stacking line is computer programmed with CAD optimized designs. The design process computerized automatic precision process, cutting, stacking and handling, and the highest quality high permeability, grain oriented silicon steel, all contribute to achieve a consistently high core quality with the lowest possible losses and sound levels, and at an economic cost. 3D CAD modeling insures parts fit exactly prior to assembly Core Cutting Equipment Cruciform construction, nearly round, enables minimal dimensions for lowest losses and optimal coil fit, thereby optimizing total transformer material utilization and operating energy cost. Automatic, precise Core Stacking Equipment stacking also assures minimal stress, consistent quality with higher efficiency and lower noise. Mitered step-lap construction with precision joints allow efficient flux Core Assemblies transferring along natural grain oriented lines, enhancing efficiency by reducing joint fringing, thereby reducing losses and exciting current and yielding the lowest sound levels. Mitered Step-lap construction
Coil Manufacturing Process JST s coils are produced with state-of-the-art, computer automated, winding and casting equipment from Germany using the highest quality copper or aluminum conductor and insulation materials used in UL certified insulation systems systems. Stollberg secondary winding machine, is computer automated and features conductor under constant tensioning, and precision, automated welding of copper or aluminum strip and LV terminal, ensuring consistently hi h quality high lit coils. il Casting is the most critical step for ensuring coil winding quality and integrity and the guarantee that a transformer will perform reliably, longterm, under the most demanding applications and severe environmental conditions. Extensive testing and JST's extremely high reliability record clearly demonstrate that JST's vacuum cast resin transformers meet all criteria for serving under the most demanding conditions. Consistency of the casting Stollberg primary winding machine is computer controlled and features controlled tensioning and precision wire laying ensuring consistently high quality coils. process is made possible by a modern, computer controlled, high capacity, casting system supplied by Hubers of Germany, the most proven technology globally. This state-of-the-art vacuum casting system employs static mixing, a process that delivers a constant viscosity, uniform, gas free resin mixture to pre-heated molds, which are filled from the bottom, under vacuum, all in a climate-controlled room. Curing in time-temperature controlled ovens results in perfect, solid, void-free castings, with the resin completely saturating all of the insulation and tightly holding the winding in place, assuring long-term reliable operations, under the most crushing forces of short circuit and Di l t i iintegrity, t it power surges. Dielectric important for basic impulse level (BIL) and lightning or switching surge applications, is assured by the solid resin block being impervious to moisture and environmental contaminants. HV Coil Coil Cross-Section Hubers computer controlled casting system Coil top view
Manufacturing Facilities...
Manufacturing Facilities... Inspection of JST s manufacturing facilities clearly reveals key ingredients for exceptional quality. Cleanliness throughout. Strict attention to process and quality control procedures. Planned, orderly flow. Design and testing to either ANSI or IEC specification. Extra protection for safe shipment to customers around the world.
Features Quality is Built In. And It Shows JST s are known for Fit. JST transformers f k f their h i superior i Fi Finish and Functionality. JST Core-Coil assemblies are designed for optimized performance and value. For greater cooling capacity needed in higher power transformers, axial ducts are added in HV coils providing more cooling surface thus enabling greater optimization. Photos show higher kva ducted and lower kva non-ducted coils. Coils are supported on the top and bottom with epoxy blocks, cushioned with resilient pads to permit expansion and contraction. Upper jack-bolt assemblies provide uniform pressure to contain coil movement. Details make JST s transformers better. For example, bottom coil blocks are pinned to the lower core clamps to prevent them from shifting or falling out. Top coil blocks are recessed to capture the jack-bolt plates. T and Top d bottom b tt blocks bl k are machined hi d tto provide id permanentt high-low space separation of the coils, helping to maintain consistent dielectric performance. Fan superiority is also evident. Fans are constructed of stainless steel and with squirrel cage air delivery system, and can deliver up to 50% additional transformer capacity, the highest in the industry. We can comply with Buy America and ARRA requirements Our Carlstadt, NJ facility
Cast Coil Specification Guide 1.0 General The transformer shall be cast coil, drytype construction, manufactured and tested in accordance with applicable industry standards prepared by the National Electrical Manufacturer s Association (NEMA) and the American National Standards Institute (ANSI). Manufacturer shall be ISO certified, have complete in-house capability to perform all ANSI required tests including impulse, temperature rise and sound level, and have at least five years experience. 2.0 Ratings kva, AA, / AA/FA, / AA/FFA, Conductor & bus copper or aluminum Primary coils are vacuum cast with Secondary coils vacuum cast or encast (hermetically sealed epoxy) Primary volts delta or wye connected, BIL kv, Phase, Frequency, Taps standard 2+/- 2.5% other Primary terminals connect to customer cables inside transformer case, HV ATC, HV switch/ breaker, busduct Secondary volts delta or wye connected, BIL kv Impedance % standard tolerance), +/-10% tolerance Secondary terminals connect to customer cables inside transformer case, LV ATC, LV switchgear, busduct Sound Level db (AA), / db (AA/FFA or AA/FA) db (standard) Temperature rise 115 C, or 80 C, or 80/115 C with continuous 15% overload capacity without exceeding maximum operating temperature, Ambient temperature C, (standard 30/40 C ) Special accessories Enclosure Indoor (NEMA 1 or NEMA 2), or Outdoor (NEMA 3R) Total Owning Cost evaluation, standard losses and efficiency or NEMA TP1 high efficiency rating or Special loss evaluation @ % load, A or NL value $ /kw, B or LL value $ /kw 3.0 Construction 3.1 HV & LV Coils The transformer shall be constructed of individually cast, co-axially mounted, primary and secondary coils. Primary coils shall be wound with copper or aluminum conductor as specified. High voltage taps shall be provided on the front of the coils, 2-2.5% full capacity above nominal (FCAN) and 2-2.5% full capacity below nominal (FCBN), and are changed only when the transformer is de-energized. Threaded brass tap inserts imbedded in the epoxy and bolted solid tin-plated bus tap links shall be furnished. Drilled bus tabs extending through the epoxy are not permitted. High voltage windings are cast in epoxy, in a mold, using pre-heat and vacuum cycles and abottominjectionfillingprocesstoassure to assure optimal saturation of the epoxy. The epoxy, rated for the same temperature as the insulation system, shall be reinforced with fiberglass. Secondary coils utilizing wire or sheet conductor are wound separately, and are either vacuum cast as the high voltage coils or encast construction, a non-vacuum process with oven cured epoxy layer to layer insulation and epoxy caps on both ends of the coil. HV and LV coils shall be designed to operate in a 30 C average, 40 C maximum ambient temperature in a 24-hour period. 3.2 Core & Coil Assembly The transformer core shall be designed to maintain flux density well below saturation and consist of Grade M-5 (minimum), high permeability, grain-oriented, non-aging silicone steel. Core shall be step-lap, cruciform construction with mitered joints. To oassue assure reduced educedsound levels esand lowest losses, core legs shall be insulated and banded with stainless steel straps and top and bottom core clamps shall utilize an insulated through-core bolting process. The assembled core shall be braced with heavy steel angle to provide uniform clamping pressure. Core and clamping structure shall be coated with high temperature enamel for environmental protection. The top and bottom of the coils shall be supported on epoxy blocks, cushioned with resilient pads, to secure them while permitting them to expand under loading. Bottom coil blocks shall be pinned to bottom core clamps to prevent blocks from moving. Manufacturer shall mark all bolted torque connections. The transformer core and coil design and construction must be verified by short circuit testing on similar units, performed in accordance with the latest revisions of ANSI Standards C57.12.01 and C57.12.91. 3.3 Accessories Fan cooling, if specified shall increase base kva rating by 33 1/3% on units up to 3750kVA and 25% on units over 3750kVA at the rated temperature rise. If 80/115 C is specified, base ratings will increase 50% up to 3750kVA and 40% on units over 3750kVA when operating at the maximum temperature rise. Thermal sensors placed in tube wells adjacent to the leads of all three LV coils shall automatically regulate forced-air cooling. Complete forced air equipment includes flush mounted three-phase electronic temperature monitor-controller with contacts for fan, alarm and trip function, fail safe maximum temperature recording, internal alarm with automatic or manual reset, programmable fan exerciser feature and blackbox, bus sized for the maximum FA rating, fans and control wiring. After exiting the LV tube wells, thermal sensors are to be routed in metal conduit-tray to prevent damage. Plastic tie-wraps are not permitted for securing the thermocouple. At a minimum, future forced air provisions shall include bus sized for the maximum FA rating, and provisions for mounting fans and controls. 3.4 Enclosure As specified, a heavy gauge sheet steel NEMA 1 indoor, NEMA 2 indoor drip-proof, proof, or NEMA 3R outdoor enclosure shall be supplied. The design shall permit the enclosure to be disassembled and reassembled, and the core-and-coil assembly removed from its base in the field without cutting or welding. Resilient pads mounted below the core-and-coil assembly shall effectively dampen vibrations to the transformer enclosure. Equip enclosures with removable bolted panels on the front and rear for internal access. Indoor ventilated openings or outdoor louvers shall comply with NEMA and NEC standards. The heavy steel enclosure base shall include provisions for rolling, skidding, lifting, and jacking. A flexible grounding strap shall be used to visibly ground the core to the frame. Enclosure finish shall be ANSI 61utilizing dry powder, electro-static process. 4.0 Testing Testing shall comply with the latest revisions of ANSI C57.12.01 and ANSI C57.12.91. Each transformer shall receive the following tests: Ratio, Polarity, Phase Relation, No Load Loss, Excitation Current, Impedance Voltage, Load Loss, Applied Potential, Induced Potential and Partial Discharge test (for coils over 600 volt). Windings shall be tested for partial discharge at 120% of rated voltage, with 10 Pico-Coulomb maximum extinction level. Impulse, sound level, temperature and short circuit test results shall be available upon request from previously tested similar designs.