Products » Inflatables » Aircell

 

 

Zena-Cell

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 o 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 minimise 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 ageing of the insulation system.

Aircell
   

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. Connecting Flange

  2. Pipe Connecting Breather

  3. Straps

  4. Zena-Cell (Air Cell)

  5. Conservator

  6. Oil Level Indicator

  7. Float Arm

  8. Float

 

The product design and construction of Zena-Cell® 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 Zenith's 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:

Zenith's 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:

  • High bonding strength between rubber to fabric

  • Improved temperature and ozone resistance

  • Good swell and chemical resistance to transformer oil

  • Crack and weathering resistance

   

The Coating Technology:

Unlike other manufacturers we have our own fully integrated and most sophisticated manufacturing facility to produce rubber coated fabrics, which are roto-cured under automatically controlled time, pressure and temperature. This distinctively offers advantages such as:

 
  • 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.


In-house manufacturing of accessories:

Unlike other Air Cell manufacturers, all the accessories such as Flange, Sealing Tape, Rubber Strip,Diaphragm and Adhesives are made in-house under our quality control.

World class quality and the well-evolved rubber technology at our command is underscored by an ISO 9001 Certification and ISO 14001certification covering all major criteria i.e. Design, Development and Production. This reassures our clientele a consistent quality and on-time deliveries. Each air cell endures a four day test procedure where it is checked, rechecked and double checked for leakages under pressure and proper performance leaving no doubt in our customer’s mind regarding the dependability of the product.

   

Routine Tests

Type Tests

Basic Fabric:
  • Visual Inspection for Knots & Holes

  • Breaking Strength

  • Elongation


Coated Fabric:

  • Air permeability

  • Visual Inspection for Pin-holes

  • Mass Surface

  • Thickness

  • Swelling

  • Tear Strength

  • Breaking Strength

  • Elongation

  • Adhesion


Finished Product:

  • Pressure Testing by Compressed Air
  • Leakage Testing with Soap Solution
  • Puncture Testing

Coated Fabrics for:

  • Heat Ageing

  • Compression Test

  • Low Temperature Flexibility

  • Sludge Content

  • Acidity

  • Ozone Resistance

  • Air Permeability


Test Certificates can be provided upon request

   

Faults & Remedies

Zena-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 the our manufacturing facility.

   
 

The dimensions of the separators are based on the size of the conservator which are generally cylindrical in shape. The most used dimensions are tabulated for ready reference. Other dimensions and shapes such as elliptical, square and custom designs can also be manufactured upon request

 
 
 
   

Order

Your requirements can be specified by giving dimensions L, W & LD

   
SR. No. Code Expansion Volume CONSERVATOR SIZE SEPARATOR SIZE
       Dia  Length  Volume  Width  Length  Loop Dist
     (Litres)  A (mm)  B (mm)  Ltrs,  W (mm)  L (mm)  G (mm)
1 ZC 500 500 500 500 2710 530 825 3035 2010
2 ZC 500 600 500 600 1970 560 982 2352 1170
3 ZC 750 600 750 600 2850 810 982 3232 2050
4 ZC 750 700 750 700 2180 840 1140 2620 1480
5 ZC 1000 700 1000 700 2830 1090 1140 2620 1480
6 ZC 1000 800 1000 800 2167 1088 1290 2657 1167
7 ZC 1500 800 1500 800 2260 1130 1297 2757 2060
8 ZC 1500 900 1500 800 3250 1630 1297 3747 2250
9 ZC 2000 900 1500 900 2660 1690 1454 3214 1560
10 ZC 2000 1000 2000 900 3440 2190 1454 3994 3240
11 ZC 2000 1000 2000 1000 2400 1884 1610 3010 1200
12 ZC 2000 1000 2000 1000 2990 2347 1610 3600 1790
13 ZC 2500 1000 2500 1000 3300 2590 1610 3940 2100
14 ZC 2500 1000 2500 1000 3400 2669 1610 4010 2200
15 ZC 2500 1000 2500 1000 3540 2779 1610 4410 2340
16 ZC 3000 1000 3000 1000 3800 2983 1610 4410 2600
17 ZC 2000 1000 2000 1000 2880 2660 1611 3491 1680
18 ZC 2500 1000 2500 1000 3520 2760 1611 4131 2320
19 ZC 3500 1000 3500 1000 4740 3721 1611 5351 3540
20 ZC 2500 1100 2500 1100 3000 2850 1768 3668 1700
21 ZC 3000 1100 3000 1100 3520 3350 1768 4188 2220
22 ZC 3000 1200 3000 1200 3050 3450 1925 3775 1650
23 ZC 4000 1200 4000 1200 3940 4450 1925 4665 2540
24 ZC 3500 1300 3500 1300 2800 3715 2082 3582 1300
25 ZC 4000 1300 4000 1300 3450 4580 2082 4232 1950
26 ZC 4500 1300 4500 1300 3600 4775 2082 4382 2100
27 ZC 5000 1300 5000 1300 4000 5307 2082 4782 2500
28 ZC 5000 1300 5000 1300 4200 5580 2082 4982 2700
29 ZC 6000 1300 6000 1300 4770 6328 2082 5552 3270
30 ZC 8000 1300 8000 1300 6520 8650 2082 7302 5020
31 ZC 3000 1300 3000 1300 2512 3332 2100 3300 1110
32 ZC 5000 1400 5000 1400 3710 5720 2239 4549 2110
33 ZC 6000 1400 6000 1400 4360 6720 2239 5199 2760
34 ZC 6000 1400 6000 1400 5000 6633 2440 5840 3400
35 ZC 6000 1500 6000 1500 3900 6880 2396 4796 2200