Dry-type transformers

RESIBLOC®
Transformer technology
reducing environmental impact
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Environmental protection,
reliability, and enhanced safety
The challenge In addition, the glass-fibers extend the range of temperatures at
Hitachi Energy offers a complete portfolio of dry-type which the transformer can be utilized; unrestricted use is
transformers utilizing unique and proven technologies, which possible even at a temperature of -60°C.
meet the varying needs of customers across various segments
and applications. A reliable transformer technology is essential Other advantages of RESIBLOC® technology relate to protection
in many industries such as nuclear, oil and gas, marine, mining, of the environment. It is entirely oil-free, and the use of other
metals, cement, pulp and paper, hydrogen, and chemical. flammable materials has also been reduced to a minimum, thus
avoiding any contamination in the transformer’s surroundings
At Hitachi Energy, we always go above and beyond. Our dry- and eliminating any additional fire risk.
type transformer solutions deliver reliability, protection, and
safety in even the harshest environments. Conventional RESIBLOC® provides a lot of potential for cost savings: its
solutions often fall short of these important requirements. special construction minimizes both the requirement for spares
inventories and the amount of maintenance work needed.
The solution
Hitachi Energy's RESIBLOC® cast-resin transformer:
• No risk for humans and the natural environment due to
contamination
• Non-explosive and flame-retardant
• Heavy load cycles (cold start to maximum load)
• High short-circuit withstand capability
• Stress due to tough ambient conditions
• Stress due to harmonics
• Overvoltage peaks
• Variable power factor control
• Minimized maintenance

With ratings of up to 60 MVA and voltages of up to 52 kV,

Hitachi Energy offers RESIBLOC® as an individually customized
product that meets all these requirements and conforms to the
international standards, IEC, ANSI, or IEEE. RESIBLOC®
transformers are certified for climate (C4), environmental (E4),
and fire (F1) classes in accordance with IEC 60076-11 and
undergo additional verification for the operation at -60°C
temperature.

Furthermore, RESIBLOC® technology contributes to the

protection of the environment. It is entirely oil-free, with
flammable materials reduced to a minimum, thus, avoiding
contamination and eliminating additional fire risk.

RESIBLOC® proposes total ownership savings:

• its special construction cuts down on requirements for
spares inventories and maintenance work and
• provides outstanding mechanical strength, meaning it is
ideal for use in applications involving high mechanical
stresses. For example, RESIBLOC® is ideal for use in
environments prone to earthquakes or applications with
continual shocks.
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How RESIBLOC® differs from
conventional dry-type transformers
RESIBLOC® has decades worth of proven track record in
applications requiring high-level reliability or special
environmental conditions.
What differentiates RESIBLOC® from a conventional dry
transformer is its 80 percent fiberglass content. RESIBLOC® has
outstanding mechanical strength, which makes its usage ideal
in applications involving high mechanical stresses. For example,
RESIBLOC® is ideal for use in environments prone to earthquakes
or continual shocks.
RESIBLOC® flexible production technology allows customized
transformer designs as per application needs. These include
double-tier transformers, multi-pulse transformers, multi-winding
models, single-phase transformers, and on-load or off-circuit tap-
changers.
Overload withstand capability
The high winding time constant of RESIBLOC® transformers
enables them to be operated at high short-time overload values.
This can be factored in when deciding on the rating.
It does not exceed the 155°C maximize allowable hot-spot
temperature in the winding during a brief overload if at the
beginning of the specific overload, the transformers is operated
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at partial load or if the ambient temperature is lower than the
design temperature.
Overload protection
RESIBLOC® transformers are equipped with a temperature
warning system to avoid thermal overloading due to high
ambient temperature, inadequate temperatures, inadequate
cooling, and overload operation. As a standard feature, the
temperature relay monitors up to three sensors simultaneously
for up to three limit values. Different sensors can also be
connected and evaluated, such as Pt100s. Also available are
monitoring capabilities for additional sensors or bus system
connections.
Forced air cooling
There is an option for fitting RESIBLOC® transformers with
quiet-running crossflow fans. During long overload periods, they
can improve the transformer’s power output by up to 40 percent
of its rating. Fan utilization is controlled automatically using
sensors.
Operation at -60°C temperature
The fiberglass of RESIBLOC® transformers extends the range of
temperatures at which the transformers can be utilized.
Unrestricted use is possible even at a temperature of -60°C.
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The technology
The RESIBLOC® cast-resin transformer is a path-breaking innovation in the field
of naturally cooled dry-type transformers. The RESIBLOC® technology has been
continually design enhanced.
Fiberglass reinforcement – a guarantee against
crack formation
Epoxy resin, reinforced with fiberglass rovings, is a material of
superior mechanical and dielectric strength. The low- and high-
voltage windings are positively joined to create a single
compact block. This design gives RESIBLOC® a higher short-
circuit withstand capability compared to conventionally dry-type
transformers. This unique technology protects the transformer
against crack formation even when exposed to extremely tough
operating conditions.
Low-voltage winding
Aluminum or copper foils are used for the low voltage winding of
the RESIBLOC® transformer with a winding insulation of thermal
class F. The foil winding concept ensures a significant reduction
in axial short-circuit forces. Low-voltage windings for
transformers with a relatively low rating are constructed as layer
windings to increase the filling factor.
High-voltage winding
The layered design ensures outstanding lightning impulse
voltage withstand capability thanks to its linear impulse voltage
distribution. Round (or rectangular, as i the case of the more
sizable cross-sectional areas) conductors are made of
aluminum or copper. The windings' layer insulation and outer
encapsulation are made from fiberglass-reinforced epoxy resin
of thermal class F. The individual conductor layers are coated
using the roving wet winding process. After the winding
operation is completed, the block windings are hardened in
special ovens.
The high-voltage winding is wound directly onto its low-voltage
counterpart. The positive connection between the high- and
low-voltage windings can be relied upon to prevent the windings
from shifting axially or radially against each other when exposed
to short-circuit forces. The mutual spacing between the high-
and low-voltage windings, important for the dielectric strength,
is assured even in the event of a short-circuit or after a lengthy
period in transit.
The high fiberglass content of around 80 percent and the
combination of radial rovings and axial-reinforcement fiberglass
contents creates a mechanically sturdy winding block exhibiting
very high radial and axial strength. This can be relied upon over
the transformer’s entire lifetime to prevent crack formation,
which different thermal expansion coefficients can cause for the
solid insulation and the conductor materials or by temperature
differentials in the solid insulation sheath.
This is also applicable under extreme operating situations, such
as low ambient temperatures or sudden peak overloads.
Since no molds are required for manufacturing a RESIBLOC®
transformer, windings can be individually dimensioned to a
customer’s specific requirements. To ensure adequate cooling,
for example, axial cooling channels can also be incorporated in
the windings.
Core construction
The construction of the core is one of the main drivers
determining the quality of a transformer. The material used and
its geometrical configuration substantially influence loss figures
and noise emissions. For the core of RESIBLOC®, grain-oriented
transformer laminations are used, which are layered to form leg
and yoke stacks. Meticulous dimensional accuracy ensures that
noise emissions and losses are rigorously minimized.
The joints between the leg and yoke laminations are executed
with 45° cuts and arranged in overlapping layers to ensure
optimum matching of the flow pattern to the magnetic
preferential direction. In modern-day step-lap technology, the
joints between the leg and yoke laminations exhibit multiple
offsets. An epoxy resin coating protects the core against
potential corrosion.
Climate, environmental, and fire classes
The standard versions of RESIBLOC® dry-type transformers
meet the most stringent requirements for climate,
environmental, and fire classes certified as C4, E4, and F1 in
conformity with IEC 60076-11, with an additional verification of
operation at -60°C. RESIBLOC® dry-type transformers can
directly access environments with a high density of industries
and environments exposed to strong wind from the sea, such as
offshore oil and gas applications.
The RESIBLOC® cast-resin transformer is
available for ratings of up to 60 MVA and
insulation voltages of up to 52 kV
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Integrated production processes

The production of RESIBLOC® transformers is guided by an
testing in accordance with international standards and
integrated management system designed to maximize efficiency
additional tests can be arranged upon for each specific project.
while minimizing its impact on the environment and ensuring the
safety of employees.
Once manufactured, Hitachi Energy can support customers
with a comprehensive range of services for delivery,
Each RESIBLOC® transformer is subjected to comprehensive
commissioning, and extending beyond the warranty period.
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Comprehensive service support

The delivery package for RESIBLOC® includes more than just

the transformer itself. Customer will receive guidance from a
team of knowledgeable engineers to ensure all technical details
are understood and the best solution for a specific application
is delivered. Customers can confidently trust Hitachi Energy's
experience gained from exposure to a wide range of transformer
applications.

Hitachi Energy team can carry out maintenance jobs on-site

during the transformer's entire operating lifetime, such as
professional cleaning routines or tests for analyzing the
transformer's ongoing condition. This is useful for safeguarding
against failures and improving system dependability.

In addition, Hitachi Energy offers retrofit services on site, such

as replacing or retrofitting specific components, even an entire
coil, if needed. Accessory parts such as converters, fans, or
rain roofs can also be retrofitted to meet the changing
requirements, as needed.

Hitachi Energy's service capabilities are

available to customers all year round,
ensuring operation reliability and
confidence.
Hitachi Energy
Customer Connect Center

www.hitachienergy.com/contact-us

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©Hitachi Energy 2021. All rights reserved.
Specifications subject to change without notice. 5233 EN Rev. A – printed in Germany (05.21)