Dry Type Brochure
Dry Type Brochure
Dry Type
Transformers
LNG Plant
Rapid Transit
City Lights
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The dry type transformers have been made in the
USA since the 1950’s using NOMEX high temperature
insulation from DuPont. The development of this
technology was aimed at the improvement of safety,
reliability, and the life of transformers for industrial and
commercial applications. The varnishes and processing
technology for achieving the highest level of reliability
and long life was developed in the 1960’s. VTC started
manufacturing dry type transformers using 220 ºC
insulation systems in the early 1970’s. Over the years,
design and processing technology at VTC has been withstand outdoor rain and snow conditions and those
developed to manufacture transformers up to 15,000 that isolate the transformers completely from the
kVA up to 35 kV class. VTC’s dry type transformers environment around it. Our systems meet and exceed
have been manufactured for applications in buildings, the American standards requirements per ANSI -C57.
airports, hotels, public buildings, and industrial plants Over the years, Virginia Transformer Corp has developed
such as automobile, steel, textile, paper, mines and data the process and the technology to use aluminum
centers. conductor in the coils. This produces a lower cost than
In Mexico, VPI dry type transformers are marketed by copper windings with the same performance. The
Virginia Transformer under the trademarked logo Silver aluminum conductors are joined with TIG welding to
Star®. VTC designs each transformer for the given assure high reliability and long life.
specification and application presented by the customer. Coils are wound in environmentally controlled winding
Various parameters of the design are optimized to rooms to maintain the highest performance level
produce the most efficient and cost effective design. of the coils. The core is cut on automatic specially
VTC dry type transformers are self extinguishing and designed core cutting machines, in a temperature
non polluting. These are the GREEN transformers. controlled environment to produce the lowest core
loss performance.
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Processing for Coil Protection:
VPI: The coils are dried, and then sealed with thermoset Enclosures:
polyester varnish under vacuum conditions. This quality is
achieved at the factory, results in a completely sealed coil. The NEMA 101: Clean indoor applications
process requires proprietary processing of vacuum temperature
and pressure. NEMA 103R: Outdoor applications per ANSI
standards C57.12.55
VPI End Cap: The ends of the coils are sealed with special
formulations of resins to provide rigid support to withstand axial NEMA 103 R – Coastal Applications per ANSI
impact found in industrial applications. Standard C57.12.59
Unidip: A proprietary process used to seal the coils with a TENV – Totally Enclosed Non Ventilated –
thick resilient coating. This coating is impervious to mois- Indoor/Outdoor Application where corrosive
ture, thus it will keep moisture from diffusing into the coils. gasses, high dust and other contaminants are
The construction enhances the life of the transformer in all
applications. present. This meets the requirements of
NEMA 12 without the welding.
UNIClad®: The coils are totally impregnated with a resin
mixture that is filled with compounds to fill the smallest
crevices in the coil under vacuum. The result is void free
coils in which the turns are supported solidly to withstand
the worst industrial mechanical impact due to the applica-
tion and handling.
The life expectancy of the coils increases progressively with
improved processing. The UNIClad coils are designed to last
40 years
The application engineers at our National Sales Office will offer assistance in assuring the best process and enclosure for your application
TYPICAL APPLICATIONS
COIL OPTIONS
• Subway & rapid transit
Coil Shape Coil Configurations Coil Sealing • Hospitals, hotels & schools
• Rectangular • Delta-Wye • Polyester • Utilities & power plants
• Circular • Chemical Plants
• Zig-Zag varnish VPI
Coil Winding • Mining operations
• Wye-Wye • VPI and epoxy
• Paper & steel mills
• Barrel end caps
• Delta-Delta • Oil & gas refineries
• Disc • Unidip
• Phase Shifters • Office & shopping complexes
Coil Conductors • UNIClad® • Manufacturing plants
• Aluminum
• Airport terminals
• Copper • Water treatment plants
• Research facilities
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AUDIBLE SOUND LEVELS TOTAL COIL TEMPERATURE
Forced Air Average Temp. Rise
Less than Self Cooled Cooled by resistance 150 ºC 115 ºC 80 ºC
1.2 kV Ventilated Ventilated Ambient Temp.
kVA (ST20) (TR1) (TR1) (Maximum) 40 ºC 40 ºC 40 ºC
301-500 60 60 67 Hotspot Temp.
501-700 62 62 67 Allowance (est.) 30 ºC 30 ºC 30 ºC
Total Temp.
701-1000 64 64 67
of Coil 220 ºC 185 ºC 150 ºC
1001-1500 65 65 68
1501-2000 66 66 69
TRANSFORMER FEATURES
2001-3000 68 68 71
Range - Up to 15/20 MVA, 35 kV voltage class,
3001-4000 - 70 73
150 kV BIL
4001-5000 - 71 74 Loading - Designed to deliver rated current and
5001-6000 - 72 75 MVA in all tap positions
6001-7500 - 73 76 Service - Outdoor or Indoor
Basic Impulse Level (BIL) - Per ANSI standard
Coils - Aluminum or copper conductor, circular or
APPLICABLE STANDARDS rectangular construction, disc or barrel wound
ANSI - American National Standards Institute Coil Sealing - Vacuum Pressure Impregnated (VPI)
Insulation - 220 ºC Insulation system
IEEE - Institute of Electrical and Electronic Engineers
Enclosure - NEMA 101/103R:, Complete
C57.12.01 - General Requirements for Dry Type
breakdown crowned roof for water shedding base
Transformers suitable for lifting, jacking and skidding
C57.12.51- Requirements for Ventilated Dry Type Paint - ANSI 61 enamel on phosphatide cleansed
Power Transformers 501 kVA and Larger, Three Phase, surface
with High Voltage 601 to 34,500 Volts, Low Voltage
208Y/120 to 4160 Volts Nameplate - engraved stainless steel for outdoor
C57.12.52 - Requirements for Sealed Dry Type use, metallized mylar adhesive for indoor
application
Power Transformers 501 kVA and Larger, Three Phase,
Stainless steel ground pads
with High Voltage 601 to 34,500 Volts, Low Voltage
12/18 month standard warranty
208Y/120 to 4160 Volts Options
C57.12.91 - Test Code for Dry Type Distribution and • Electronic temperature monitor
Power Transformers • Load break switches
C57.94 - Practice for Installation, Application, • Matching to all OEM switchgears
Operation and Maintenance of Dry Type General • Drive/Rectifier duty up to 36 pulse
Purpose Distribution and Power Transformers 4 Paint Systems Available
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Dielectric Insulation levels for dry-type transformers used on systems
with BIL ratings 200 kV BIL and below
Nominal Basic lightning impulse insulation levels (BIL ratings)
L-L Low-frequency in common use kV crestb,c
system voltage (1.2 x 50 µs)
voltages insulation level*
(kV) (kV rms) 10 20 30 45 60 95 110 125 150 200
0.25 2.5 None
0.6 3 Sd 1e 1
1.2 4 S 1 1
2.5 10 S 1 1
5.0 12 S 1 1
8.7 19 S 1 1
15.0 34 S 1 1
18.0 40 S 1 1
25.0 50 2 f
S 1 1
34.5 70 2 S 1
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Custom Design Means the
Accessories You Want
TEMPERATURE MONITORING
Temperature monitoring is available by selecting digital or analog temperature
gauges for one or three phases with multiple NC or NO contacts. SCADA interface
is also available. An NC or NO Over Temperature Thermostat can be located in the
center coil or in all three coils and wired to a terminal board.
Temperature gauges
COOLING
Dry-type transformers can be self-cooled through ventilation in the enclosure
(AA). An automatic fan cooling package (FA), complete with temperature gauge
will increase the KVA rating by 25 or 33 percent to handle overloads. Packages
to increase KVA up to 50 percent are available with either an internal or external
power source. Fans also can be added at a later date (FFA).
Cooling fans
Terminations
A wide variety of termination arrangements are available. HV can be on the right
or left as required, while voltage taps are accessible from the front via a removable
panel. Special flanged throats and flexible connectors to external bus also are available.
Flex connector
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Totally Enclosed, Non-Ventilated
(TENV) DESIGNED FOR THE JOB AT HAND
Our TENV
THE TENV SOLUTION, DESIGNED FOR transformer
YOUR APPLICATION enclosures are
For nearly two decades, Virginia Transformer not ventilated,
thereby
Corp (VTC) has been bringing its customers
preventing
the best of both worlds: cost-effective the core and
solutions for difficult environments. Our coil from
overloads, special BIL level, and other unique to most corrosive environments and are practically
maintenance-free.
requirements.
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SUPERIOR MATERIALS, SUPERIOR ADVANTAGES
CONSTRUCTION Totally enclosed, non-ventilated construction
VTC engineers design to minimize core losses. We ensures that ambient contamination
design and construct coils appropriate to the kVA rating never contacts the 220 ºC rated core & coil
of the transformer. After winding, we dry and preheat assembly.
our coils to remove moisture, then move them into our • Install TENV indoors - or outdoors.
• TENV offers all the advantages of dry type
VPI tank where a high vacuum enables polyester resin
transformers - lower cost, ease of
to flow into the coil, filling voids. We then use positive
installation and maintenance.
pressure to drive resin into the coil. After impregnation
• With TENV, there is none of the
we bake the coils to cure the resin and form a solid environmental of fire risk inherent with
mass. VTC can also provide TENV transformers with our liquid filled units
premium UNIClad® core and coil assembly.
VTC terminates HV and LV windings inside the enclosure
APPLICATIONS
or within full or partial height air terminal chambers.
TENV transformers are an excellent
choice for :
Where the application demands it, we provide bushings
• Chemical plants
similar to those provided with liquid filled transformers.
• Cement plants
All of our TENV transformers come with a winding
• Environments with contaminants such as:
temperature gauge as a standard accessory. We also • Gases, including chlorine and sulfur
offer surge arrestors, current transformers (CTs) and • Solids such as coal dust, metal dust and
potential transformers (PTs) as optional accessories. textile fibers
• Fumes and vapors in industrial plants
• Salt-laden air
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UNICLAD® DESIGN INTEGRITY, EVEN IN
TOUGH ENVIRONMENTS
Since 1983 Virginia Transformer Corp (VTC) has
offered a superior encapsulated dry type transformer
that withstands the toughest environments. We call
it UNIClad®. Our customers know it as the system
that offers unmatched design integrity and strength
compared to traditional cast coil products. UNIClad®
is simply the best choice for your applications with
high humidity, contaminated conditions, short-circuit
loading and impact loading. And you will spend less
for UNIClad® than a conventional unit because we
design exactly what you need. With VTC, you never
BETTER DESIGN MEANS LONGER UNIT LIFE have to overbuy simply because what you need isn’t
By filling the coils with low-viscosity 100% solid standard.
polyester varnish under vacuum and pressure, VTC VTC unveiled UNIClad® in the early 1980’s to
also assures void-free coils. UNIClad® coils exhibit address the growing need for a product that could
very low discharge levels, which means longer life, outperform traditional systems. Standard cast coil
a reduction in the possibility of internal dielectric construction can withstand short-circuit forces, but
failure, and partial discharge-free operations its brittle epoxy construction is prone to cracking
maintained for the life of the transformer. We from thermal, mechanical and electrical forces. This
seal coil ends using an evacuated resin system cracking allows moisture and corrosion to attack the
formulated to match the coefficient of thermal coil causing failure. Our UNIClad® coils withstand
expansion of the coil. thermal cycling forces, short-circuit shock and
UNIClad®’s 220 ºC insulation system and 115 ºC operating core vibration without cracking, thanks to
temperature rise design provides a continuous our unique encapsulation and sealing process. We
overload capability of approximately 15%. Even completely seal UNIClad® coils with a 220ºC-rated,
under overload conditions UNIClad® will maintain flexible polyester varnish applied under vacuum and
temperatures within the insulation rating. The solid pressure.
filling or our coils improves thermal conductivity, This tough, flexible cladding material is also highly
allowing the coils to run cooler and resulting in chemical and moisture resistant. Besides our vacuum
longer unit life. On average, the life expectancy sealing process, VTC uses NOMEX on UNIClad® coils to
of a UNIClad® is 40 years at a constant rated ensure flexibility of the insulation system and highest
load, subject to proper application, protection, thermal rating for the longest life. UNIClad® can even
maintenance and duty cycle. withstand total water immersion for 24 hours with no
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UNICLAD® CUSTOM DESIGNS SAVE MONEY UNICLAD®: THE PREMIUM ENCAPSULATED
VTC custom designs all UNIClad® units, resulting
DRY TYPE TRANSFORMER
• Epoxy sealed coil (top and bottom) - evacuated
in significant dollar savings to you. We simply
resin system formulated to match the coefficient of
don’t believe in forcing customers to choose from thermal expansion of the coil.
pre-determined molds, designs, or specifications. • Flexible, polyester insulation system allows coils to
withstand mechanical and thermal shocks
Such one-size-fits-all product offerings often force
• UL listed 220 ºC rated insulation system for turn and
customers to “size-up” their unit, wasting money and
layer protection
taking up extra space at their site. • Vacuum and pressure processed coils reduce
With UNIClad®, you’ll pay only for what you need. operating temperature and corona level
• Tough, flexible polyester cladding assures reliable
And you can expect delivery of your UNIClad® system
operation in contaminated and humid environments
in about half the time needed for standard cast coil
• Circular coil construction for best short-circuit and
units thanks to our commitment to global sourcing. impact-loading strength
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UNICLAD® VS. CAST COIL: THE CHOICE IS CLEAR
VTC developed UNIClad® to operate under demanding applications in increasingly harsh environments.
Because it is designed to withstand industrial fumes and vapors, fibrous and particle contamination, high
temperature and humidity, short-circuit forces, and electrical impulses, UNIClad® is the cost effective
alternative to liquid filled or cast coil transformers. UNIClad®. For power, rectifier, drive isolation and
generator exciters up to 15 MVA, 35 kV class.
WHY HAVE CAST COIL RESIN WHEN YOU CAN HAVE UNICLAD®?
Desired Features UNIClad Cast Coil
High Thermal Rating Excellent-220º Acceptable - 150º C – 185º C
Overload Capability Very Good - 15% overload without fans Limited -Fans necessary for overloading
Seal Integrity Yes – Flexible insulation and cladding system No – Cracking of coils because of rigid
eliminate coil cracking casting and high thermal coefficient of
expansion of epoxy
Void-Free Coil Void density is low because of low varnish Void density is higher because of high
viscosity and vacuum/pressure process viscosity of epoxy resin
Superior Short Circuit Yes – Performed with 0% impedance change No – Passes standard ANSI test of 4 tests of
Test Performance in a 4-second duration test, 60 times longer 4 cycles (60 hz.) each, with less than 2%
than required per ANSI standards impedance change
Flexible Designs Yes – All UNIClad® units are designed to No – Must choose from existing molds
customer specifications
Competitive Pricing Yes – Never need to “up-size”; UNIClad® units Sometimes – Choosing from pre-set molds
are designed exactly for customer applications can result in a 10-15% premium because
any nonstandard designs may force
customer to order larger size unit
than actually needed
Basic Impulse
Level (kV) Standard (kV) Optional (kV) UNICLAD® BENEFITS
1.2 10 20, 30
• Impressive 3-year warranty
2.5 30 45
• Circular design above 750 kVA
5.0 45 60 • 220 ºC insulation class
8.7 60 95 • 15 percent overload capacity
15.0 95 110 without fans at 115 ºC rise
25.0 125 150 • Partial discharge free to 120 %
34.5 150 - • Water submersion 24 hours
Insulation System 220 ºC (Nomex Based) - • Thermal Shock - no cracks
Winding Temperature Rise 115 ºC 80 ºC, 150 ºC • Humidity 100% for 48 hours
Impedance 5.5% - 7.5% depending on HV BIL and LV rating • Vibration 1.5 Gs
Forced Air Rating (kVA) • Shock 30 Gs
133% -
133% 150%
Ambient Temperature Range -40 ºC to +40 ºC Max +50 ºC
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TRANSFORMER FEATURES
Range - Up to 15 MVA, 35 kV
voltage class, 150 kV BIL
Loading - Designed to deliver
rated current and MVA in all tap
positions
Service - Indoor/Outdoor
Basic Impulse Level (BIL) -
Per ANSI standard
Impedance - ANSI Standard
Coils - Aluminum or copper
conductor, circular construction
Paint - ANSI 61 enamel on
phosphatized cleansed surface
Nameplate - Metallized mylar
Other - Provisions on base for
lifting, jacking and skidding,
stainless steel ground pads
OPTIONAL FEATURES
• Reconnectable windings
• Non-standard impedance
• Fan cooling for increased MVA
• Available at 80 ºC or 150 ºC rise
• 4 Paint systems available
• Outdoor, NEMA 103R enclosure
• Temperature Monitoring - Choose
from coil winding temperature
sensors and indicators, gauges or
temperature controllers
• Terminations - Copper or aluminum
bus with NEMA hole patterns
and optional plating, flexible bus
connection provisions also available
• Special flanged throats or custom air
terminal chambers
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Data Center
Manufacturing Plant
Airport
Hospital
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Pocatello, ID
Liquid Filled:
Up to 100 MVA/230 kV
Roanoke, VA
Dry Type:
Up to 15 MVA/34.5 kV
Liquid Filled:
Up to 25 MVA/115 kV
Chihuahua, Mexico
Dry Type:
5 MVA/34.5 kV
Liquid Filled
10 MVA/69 kV
Manufacturing Plants
Roanoke, VA – 220 Glade View Drive, Roanoke, VA 24012
540.345.9892 • Fax 540.342.7694
Pocatello, ID – 3770 Poleline Rd. Bldg #37, Pocatello, ID 83201
208.238.0720 • Fax 208.238.1678
Chihuahua, Mexico – Complejo Industrial Chihuahua, Ave. Homero #3307, Chihuahua, Mexico
52.614.483.0000 • Fax 52.614.481.4900