TUV India Private Ltd.
ISO
9001 SUKRUT
AIRCELL
FOR OIL FILLED TRANSFORMERS
OVERVIEW
The Air Cell (Flexible Separator) is fitted inside a conservator tank, isolating insulating oil
from the atmosphere, and thus preventing contamination of gas and/or moisture from coming in to
contact with the transformer oil due to oxidation and hydrolysis. The bag is vented on the
transformer through flange type mounting such that it inflates or deflates to accommodate oil
volume displacements due to changes in the transformer temperature.
The Air Cells are manufactured using time tested combination of Nylon (Polyamide) fabric
and thick coating of Elastomers i.e. Acrylonitrile Butadiene Rubber (NBR), Polychloroprene (CR)
and Hypalon (CSM). The rubber compounds are so formulated, so as to minimize separator
degradation and resist leakage of air through membranes thus reducing the amount of air in the
transformer oil. Over a period of time this air/gases can reduce dielectric strength and thereby
accelerate the aging of the insulation system.
The advantages of the Air-Cell can be well concluded from the facts :
Simple design with no expandable parts
Needs negligible man hours for inspection
Extended service life
Economical
Prevents corrosion
Oil can be filled into the transformer tank without being exposed to the air
Since insulating oil is completely isolated from the atmosphere by an air cell, there is no
Possibility of oxygen or moisture penetrating the oil
Pressure on the surface of the oil is constantly maintained at the atmospheric pressure,
offering no possibility of the oil becoming supersaturated and forming bubbles; thus,
high dielectric strength can be maintained
1 3
4
2
AIR 5
AIR
OIL 6
7
1. Connecting Flange 5. Conservator
2. Pipe Connecting Breather 6. Oil Level Indicator
3. Straps 7. Float Arm
4. Aircell 8. Float
2
THE TECHNOLOGY
The product design and construction of Aircell is based on thorough analysis of the stringent and
diverse environments in which they have to perform. Their constitution takes into account the various
factors that affect the performance over long periods of operation. The Air Cell we manufacture
incorporates the latest coating technology.
Some of the most important features that make SUKRUT Air Cell exclusive are :
The Polyamide Substrate :
The textile reinforced supporting fabric is made from high tenacity Nylon yarns and designed
specifically for flexible Separators. The fabric has high tear & tensile strength, high flexibility & fatigue
resistance and superior dimensional stability.
The Polymer Technology :
Air Cells are manufactured by using combination of various Elastomers. The inside of the fabric
is coated with combination of Olive Green-Hypalon (CSM) & Black- Polychloroprene(CR) for imparting
better ozone resistance. Whereas the outer side is coated with Black-Acrylonitrile Butadiene Rubber
(NBR) for providing better oil resistance. The compounds are carefully formulated to accommodate
critical technical parameters such as: Adhension Layer
Acrylonitrile Rubber (NBR)
a. High bonding strength between rubber to fabric
b. Improved temperature and ozone resistance
c. Good swell and chemical resistance to transformer oil
d. Crack and weathering resistance
The Coating Technology :
Our Aircells are manufactured using
sophisticated manufacturing facility to produce
rubber coated fabrics, which are roto-cured under
automatically controlled time, pressure and temperature. Hypalon (CSM) Rubber Nylon Fabric
This distinctively offers advantages such as: Adhension Layer
Aircell Fabric Construction
Higher bond strength between the polymer and fabric substrate
Hot vulcanised seams to ensure no leakage at all times
Guaranteed mechanical strength to fixation lugs
Smooth glossy surface free of pin-holes and defects due to rotocuring
Superior thickness control under tolerance of +/-0.05 mm giving greater dimensional stability.
CONSERVATOR
SEPARATOR FLANGE
3
TESTS
Routine Tests
Basic Fabric :
1. Visual Inspection for Knots & Holes
2. Breaking Strength
3. Elongation
Coated Fabric :
1. Air permeability
2. Visual Inspection for Pin-holes
3. Mass Surface
4. Thickness
5. Swelling
6. Tear Strength
7. Breaking Strength
8. Elongation
9. Adhesion
Finished Product :
1. Pressure Testing by Compressed Air
2. Leakage Testing with Soap Solution
3. Puncture Testing
Type Tests
Coated Fabrics for :
1. Heat Aging
2. Compression Test
3. Low Temperature Flexibility
4. Sludge Content
5. Acidity
6. Ozone Resistance
7. Air Permeability
Test Certificates can be provided upon request
Faults & Remedies
Air Cell is manufactured considering all aspects of application during its use in the
transformers. In the normal course of use, careful handling, storing and fitting of the Aircell will give
a good service life. However in the event of mishandling or accident the fabric can get ruptured or
the joint may open, leading to leakage of air in the conservator. For minor repairs a kit with working
instructions is provided along with each air cell. For major damage the Aircell will have to be
returned to our manufacturing facility.
The serial Number of Aircell must be informed when any observation is to be communicated
to us. Please note that it will not be possible to depute our representative to site to asses / inspect
the damage / fault.
4
DIMENSIONS & SIZES
Length (L)
Dimensions :
Loop Distance (LD)
Width (W)
Width (W)
Fixation Lugs Connector Flange Fixation Lugs
Loop Distance (LD)
Length (L)
L = Length of the Air Cell when Flat
W = Width of the Air Cell when Flat
Sizes : LD = Distance between Fixation Lugs
EXPANSION CONSERVATOR SIZE SEPARATOR SIZE
SR. NO. F S P SIZE
VOLUME
Dia Length Volume Width Length Loop Dist
(Litres) A (mm) B (mm) (Litres) W (mm) L (mm) LD (mm)
1 500 - 500 500 500 2710 530 825 3035 2010
2 500 - 600 500 600 1970 560 982 2352 1170
3 750 - 600 750 600 2850 810 982 3232 2050
4 750 - 700 750 700 2180 840 1140 2620 1280
5 1000 - 700 1000 700 2830 1090 1140 3270 1930
6 1000 - 800 1000 800 2167 1088 1290 2657 1167
7 1000 - 800 1000 800 2260 1130 1297 2757 1260
8 1500 - 800 1500 800 3250 1630 1297 3747 2250
9 1500 - 900 1500 900 2660 1690 1454 3214 1560
10 2000 - 900 2000 900 3440 2190 1454 3994 2340
11 2000 - 1000 2000 1000 2400 1884 1610 3010 1200
12 2000 - 1000 2000 1000 2990 2347 1610 3600 1790
13 2500 - 1000 2500 1000 3300 2590 1610 3910 2100
14 2500 - 1000 2500 1000 3400 2669 1610 4010 2200
15 2500 - 1000 2500 1000 3540 2779 1610 4150 2340
16 3000 - 1000 3000 1000 3800 2983 1610 4410 2600
17 2000 - 1000 2000 1000 2880 2260 1611 3491 1680
18 2500 - 1000 2500 1000 3520 2760 1611 4131 2320
19 3500 - 1000 3500 1000 4740 3721 1611 5351 3540
20 2500 - 1100 2500 1100 3000 2850 1768 3668 1700
21 3000 - 1100 3000 1100 3520 3350 1768 4188 2220
22 3000 - 1200 3000 1200 3050 3450 1925 3775 1650
23 4000 - 1200 4000 1200 3940 4450 1925 4665 2540
24 3500 - 1200 3500 1300 2800 3715 2082 3582 1300
25 4000 - 1300 4000 1300 3450 4580 2082 4232 1950
26 4500 - 1300 4500 1300 3600 4775 2082 4382 2100
27 5000 - 1300 5000 1300 4000 5306 2082 4782 2500
28 5000 - 1300 5000 1300 4200 5580 2082 4982 2700
29 6000 - 1300 6000 1300 4770 6328 2082 5552 3270
30 8000 - 1300 8000 1300 6520 8650 2082 7302 5020
31 3000 - 1300 3000 1300 2512 3332 2100 3300 1110
32 5000 - 1400 5000 1400 3710 5720 2239 4549 2110
33 6000 - 1400 6000 1400 4360 6720 2239 5199 2760
34 6000 - 1400 6000 1400 5000 6633 2240 5840 3400
35 6000 - 1500 6000 1500 3900 6880 2396 4796 2200
5
HOW TO ORDER
CYLINDRICAL CONSERVATOR
L(mm) = Length of conservator + W - Diameter of conservator
L
W (mm) = (TT x Conservator diameter) + 40 mm
2
LD (mm) = L - W - 200 mm
AIRCELL
DIA.
L: flat (fully deflated) length of the STP
CONSERVATOR
W : flat (fully deflated) width of the STP
LD : pitch distance of lugs
ELLIPTICAL CONSERVATOR
L(mm) = Length of conservator + 40 mm L
W (mm) = 1/2 developed length of the conservator)
LD (mm) = x - (H x TT) - 200 mm CONSERVATOR
2 AIRCELL
L: flat (fully deflated) length of the STP H
W
LD: pitch distance of lugs
RECTANGULAR CONSERVATOR
L(mm) = Length of conservator + 40 mm AIRCELL
CONSERVATOR
W (mm) = width of the conservator + H+ 40 mm
LD (mm) = x - (H x TT) - 200 mm H
2 L
L: flat (fully deflated) length of the STP W
LD: pitch distance of lugs
W: flat (fully deflated) width of the STP
H: conservator height
CUSTOMER SPECIAL REQUEST CONSERVATOR B
L (mm) = Length of conservator + 40 mm L
W (mm) = A+2XB +c H
2
A
A
LD (mm) = x - (H x TT) - 200 mm
AIRCELL
2
W: flat (fully deflated) width of the STP A
CONSERVATOR
H: conservator height
Your requirements can be specified by giving dimensions L, W & LD
Other Conservator Shapes Available On REQUEST
6
INSTALLATION OF THE AIR CELL
Step 1
Push the Air Cell into the conservator through the open end or inspection hatch in the end of
the conservator.
Step 2
Suspend the Air Cell from hooks (2) in the ceiling of the conservator using the loops.
Step 3
Fit the Air Cell flange (8) on the conservator flange using a ring (7) to ensure air tightness of the
system.
Step 4
Close the open end of the conservator.
Step 5
Fill the Air Cell to a pressure of 10kPa (0.1 bar). Close the filling valve (3) while leaving the
system pressurized. A relief hole (4) must be on the oil filled side of the conservator so that the
Air Cell can freely expand.
Step 6
The Air Cell will gradually stabilize. After 6 hours, adjust the air pressure again to 10kPa (0.1
bar). A 24 hours leak test is then to be made on the Air Cell. After 24 hours check the pressure
reading again. If the pressure has not dropped significantly, the test is correct. The temperature
should be as stable as possibly during the leakage testing period.
2 1 3
7
FILLING THE CONSERVATOR
Step 1
The pressure of air in the Aircell should be 10kPa (0.1 bar). If not, increase the pressure to the
correct level and close the air-filling valve.
Step 2
Check the air vent valves (4) are open at both ends of the conservator.
Step 3
Open the valve (6) between the conservator and transformer tank and pump in more oil so that
the oil rises to the conservator. The pumping speed should be suitably slow so that the pressure
within the Air Cell does not exceed 13 kPa (0.13 bar). Stop pumping, when oil begins to come
out of the vent valves and close the vent screws.
Step 4
Regulate the pressure in the Air Cell to normal by opening the plug in the flange or air filling
valve from which the pressure hose is removed.
Step 5
Reopen the valve (6) between the conservator and the transformer tank and continue filling with
oil until the oil level indicator gives the correct reading according to the temperature of
transformer.
1 2 3
SUKRUT ELECTRIC CO. PVT. LTD.
Survey No. 34, Ingale Vasti, Near Zeal Education Society, Narhe, Pune 411 041, INDIA
SUKRUT Phone
Mobile
:
:
+91 - 20 24607064 / 63 / 62
+91 7507778842, 7507677477
E-mail : [email protected]
Website : w w w.sukrutelectric.com
w w w.sukrut-group.com
