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Assembly of Power Transformer: A Summer Training Report On
Assembly of Power Transformer: A Summer Training Report On
Assembly of Power Transformer: A Summer Training Report On
Acknowledgement
1
I am extremely thankful & indebted to the numerous BHEL engineers &
technical staff that provided vital information about the functioning of
their respective departments by giving their valuable time, thus helped
me to gain the overall idea about the working of the organization. I am
thankful for the support & guidance of each of them.
The technical staff has shown great interest & were always ready to help
in understanding the working of various machineries.
I express my gratitude to HRD Department as they allowed me for training
in BHEL, Jhansi.
I am very thankful to Mr. Sushant Tiwari (BAY-09) for guiding me &
approving my project report successfully.
I would like to thank my parents, teachers & fellow trainees who have
been a contrast source of encouragement & inspiration during my studies
and provided me support in every walk of my life.
2
Abstract
3
Contents
1. BHEL
a. History
b. Overview
c. Main Manufacturing Facilities
d. Products & Services
2. BHEL, Jhansi
a. Brief Intro
b. Products
c. Upcoming Developments
3. Rotation Report
a. Sections of BHEL, Jhansi
b. TRC
c. TRE
d. TRM
e. LMC
f. LME
g. LMM
h. Store
i. Testing
4. Power Transformer Assembly
5. Power Transformer Tests
6. Conclusion
7. References
4
BHEL
History
Established in 1964.
Merged with Heavy Electricals (India) Limited in 1974.
In 1982, it entered into power equipment. Developed the capability
to produce a variety of equipment for various sectors.
In 1991, it was converted into a public limited company.
By the end of 1996, the company had handed over 100 electric
locomotives to Indian Railway and installed 250 Hydro-sets across
India.
5
An Overview
6
Main manufacturing facilities
Centralised Stamping Unit & Fabrication Plant (CSU & FP), Jagdishpur
Insulator Plant (IP), Jagdishpur
Electronics Division (EDN), Bangalore
Electronic System Division (ESD), Bangalore
Electro-Porcelains Division (EPD), Bangalore
Heavy Electrical Plant (HEP), Bhopal
Industrials Valves Plant (IVP), Goindwal
Heavy Electrical Equipment Plant (HEEP), Ranipur(Haridwar)
Central Foundry Forge Plant (CFFP), Ranipur(Haridwar)
Heavy Power Equipment Plant (HPEP), Hyderabad
Transformer Plant (TP), Jhansi
Boiler Auxiliaries Plant (BAP), Ranipet
Component Fabrication Plant (CFP), Rudrapur
High Pressure Boiler Plant (HPBP), Tiruchirappalli
Seamless Steel Tube Plant (SSTP), Tiruchirappalli
Power Plant Piping Unit (PPPU), Thirumayam
Heavy Plates & Vessels Plant (HPVP), Visakhapatnam
7
Products & Services
This plant was set up in 1974 at an estimated cost of Rs. 16.22 crores
inclusive of Rs. 2.1 crores for township.This plant of BHEL is equipped with
most modern manufacturing processing and testing facilities for the
manufacturing of Power, Special transformer and Instrument
transformer, Diesel shunting locomotives and AC/DC locomotives. The
layout of the plant is well streamlined to enable smooth material flow
from the raw material stages to the finished goods. All the feeder bays
have been laid perpendicular to the main assembly bay and in each
feeder bay raw material smoothly gets converted to sub assemblies,
which after inspection are sent to main assembly bay.
The raw material that are produced for manufacture are used only after
through material testing in the testing lab and with strict quality checks at
various stages of productions.
This unit of BHEL is basically engaged in the production and
manufacturing of various types of transformers and capacities. With the
growing competition in the transformer section, in 1985-86 it under took
the re-powering of DESL, but it took the complete year for manufacturing
to begin. In 1987-88, BHEL has progressed a step further in under taking
the production of AC locomotives, and subsequently it started
manufacturing AC/DC locomotives also.
9
Products
Transformers
Type Range
Power transformer upto 400 kV/315 MVA
Rectifier transformer upto 132 kV/120 kVA
Furnace transformer upto 33 kV/60 MVA
Transformer for ESP upto 95 kV/1400 mA
Voltage transformer upto 220 kV
Current transformer upto 400 kV
Traction transformers
Single Phase Freight Loco 25 kV/5400 kVA,6500kVA
Three Phase Freight Loco 25 kV/7475 kVA
Transformer for ACEMU upto 25 kV/1550 kVA
Single Phase 25 kV/1000 kVA
Three Phase 25 kV/1385kVA
Cast Resin Dry Type Transformer upto 33 kV/15 MVA
10
Development Project Undertaken in TRM
Project Status
220 kV Live Tank CT Status under progress
Optimization of Dry Type Material under procurement
transformer
Indigenization of Al. Tank for three RDSO approval being obtained
phase Loco transformer
0.2 accuracy class 300 UAEMVT Material under procurement
11
Sections of BHEL, Jhansi
As BHEL, Jhansi is a production plant which mainly concerns on the
production of Transformers and Locomotives, it has various
manufacturing and assembling units. The production and administrative
departments for different units are separate viz. for Transformer and
Locomotive sections the commercial, engineering and productions units
are separate.
So a brief introduction to various units of BHEL is given below:
1 Transformer Section:
1.1 Transformer Commercial (TRC):
The objective of this department is to interact with the customers related
to transformers. It brings out tenders and notices and also responds to
them. It is this department that bags contracts of building transformers.
After delivery regarding faults, this department does failures and
maintenance. All such snags are reported to them and they forward the
information to the concerning department.
The commercial department plays a major role in the progress of the
company as they have to negotiate with the customers, to satisfy them
that the company can provide them with their needs while keeping in
mind the necessary profit for their company.
One of the major tasks of this department is to earn decent profit over all
negotiations.
The main work of the TRC is classified as:
Tenders and Notices.
12
Interaction with design department.
Place of the work.
Approximate cost of the work.
Earnest money.
Place and time where contract documents can be seen.
Place and time where tender documents can be obtained.
Time up to which the documents will be sold.
Amount if any to be paid for such documents.
Place, date and time when tenders are to be submitted and are to be
opened.
Any other information relevant in tender notices.
13
Nowadays they have to do just necessary modifications according to the
requirements.
The various transformers manufactured in the TRM units are, so the
transformers that are designed here are:
Power Transformer:
Auto Transformer.
Generator Transformer.
System Transformer.
Special Transformer:
Dry Type Transformer.
ESP Transformer.
Instrument Transformer.
H V Rectifier Transformer.
Traction Transformer.
All above types are oil cooled except dry type, which is air cooled.
1.3.1.1 BAY-0:
It is an assembly shop where different parts of tanks come from
fabrication shop.
Here welding process are used for assembly, after which a rough
surface is obtained Grinder operating at 1200rpm is used to
eliminate the roughness.
15
1.3.1.2 BAY-1:
It is an assembly shop dealing with making different objects
mentioned below:
Tank assembly
Tank cover assembly
End Frame assembly
Foot assembly
Cross feed assembly
Core clamp assembly
Pin and pad assembly
Before assembly, short blasting (firing of small materials i.e. acid pickling)
is done on different parts of jobs to clean the surface before painting.
After assembly some test are done which are known as NON
DESTRUCTIVE TEST
1) Ultrasonic test: To detect the welding fault on the CRO at the fault
place high amplitude waves are obtained.
2) Die penetration test: Red solution is put at the welding and then
cleaned. After some time white solution is put. Appearance of red
spot indicates a fault at the welding.
16
3) Magnetic crack detection: Magnetic field is created and then iron
powder is put at the welding. Sticking of the iron powder in the
welding indicates a fault.
1.3.3 BAY-3:
There are basically three sections in this bay:
1) Machine section
2) Copper section
3) Tooling section
17
b) TURRET LATHE: Its function is same as central lathe but it is used
for mass production. Here turret head is used in presence of
tailstock because turret head consist many tailstocks around six.
c) CAPSTAN LATHE: It is belt drive.
d) RADIAL ARM DRILLING MACHINE: It is used for drilling and boring.
e) HORIZONTAL BORING MACHINE: It is computerized and used for
making bore, facing etc.
f) MILLING MACHINE:
a) Horizontal milling machine: It is used for making gear and
cutting operations.
b) Vertical milling machine: By the machine facing cutting and
T-slot cutting is done.
18
g) BEND SAW MACHINE: This machine is used for cutting job having
small thickness. It has a circularly operated blade, around 5.1mtr
long.
h) WATER COOLED BRAZING MACHINE: It consists of two carbon
brushes. The sheet is put along with a sulfas sheet and the carbon
brushes are heated. A lap joint is formed between the sheets as the
sulfas sheet melts.
i) LINCHING BELT MACHINE: It creates a smooth surface.
j) HYRRAULIC PRESS MACHINE: To press the job.
k) SOLDER POT MACHINE: It has a plot that contains solder. Solder has
a composition of 60% Zn and 40% Pb.
1.3.3.3 Tolling Section:
In this section the servicing of tool is done.
a) BLADE SHAPE MACHINE: It sharpens the blade using a circular
diamond cutter. Blade of CNC cropping line machine is sharpened
here.
b) MINI SURFACE GRINDER MACHINE: It serves grinding purposes. It
has a grinding wheel made of “Aluminum Oxide”.
c) TOOL & SURFACE GRINDIN MACHINE: This is specially used to grind
the tools used in bay 7.
d) DRILL GRINDING MACHINE: To grind the drills.
1.3.4 BAY-4:
This is the winding section. The winding consist of the current carrying
conductors wound around the sections of the core, and these must be
properly insulated, supported and cooled to withstand operational and
test conditions. Copper is primarily used as conductors in transformers
windings here.
19
Types of winding:
Reverse section winding.
Helical winding.
Spiral winding.
Interleaved winding.
Half sectional winding.
There are four types of coil fixed in a transformer, they are:
1) Low voltage coil (LV).
2) High voltage coil (HV).
3) Tertiary coil.
4) Tap coil.
The type of winding depends upon on job requirement. Also, the width
and thickness of the conductors are designed particulars and are decided
by design department. Conductors used for winding is in the form of very
long wound on a spool, the conductor is covered by cellulose paper for
insulation.
For winding first the mould of diameter equal to inner diameter of
required coil is made. The specifications of coil are given in drawing. The
diameter of mould is adjustable as its body is made up of wooden
sections that interlock with each other. This interlocking can be increased
or decreased to adjust the inner diameter of coil.
The moulds are of following types:
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1) Belly types.
2) Link types.
3) Cone types.
1.3.5 BAY-5:
It is core and punch sections. The lamination used in power, dry, ESP
transformers etc. for making core are cut in this section.
CRGO (Cold Rolled Grain Oriented) silicon steel is used for lamination,
which is imported in India from Japan, U.K. & Germany. It is available in
0.27 and 0.28mm thick sheets, 1m wide and measured in Kg. The sheets
are coated with very thin layer of insulating material called “caritas”.
For the purpose of cutting and punching the core three machines are
installed in shop:
1) SLITTING MACHINE: It is used to cut CRGO sheets in different width.
It has a circular cutter whose position can be changed as per the
requirement.
2) CNC CROPPING LINE PNEUMATIC: It contains only one blade, which
can rotate 90° above the sheet. It is operated pneumatically.
3) CNC CROPPING LINE HYDRAULIC: It is also used to cut CRGO sheets.
It contains two blades, one is fixed and the other rotates 90° above
the sheet. It is operated hydraulically.
1.3.6 BAY-6:
Single-phase traction transformer for AC locomotives is assembled in this
section. The freight locomotive transformers are used where there is
frequent change in speed. In this bay core winding and all the assembly
and testing of traction transformer is done.
21
Three-phase transformers for ACEMU are also manufactured in this
section. The supply line for this transformer is of 25KV and power of the
transformer is 6500KVA.
The tap changer of rectifier transformer is also assembled in this bay.
Rectified transformer is used in big furnace like the thermal power
stations.
1.3.7 BAY-7:
This is the insulation shop. The various types of insulations used in the
transformers are given a proper shape and specification in this unit.
Various types of insulation materials are:
a) AWWW (All Wood Water Washed Press Paper): The paper is 0.2-
0.5mm thick cellulose paper and is wound on the conductor for
insulation.
b) PRE-COMPRESSED BOARD: This is widely used for general
insulation & separation of conductors in the forms of blocks.
c) PRESS BOARD: This is used for separation of coils e.g. L.V. form
H.V. It is up to 36mm thick.
d) UDEL: Un Demnified Electrical Lamination wood or Permawood.
This is special type of plywood made for insulation purposes.
e) FIBRE GLASS: This is a resin material and is used in fire prone
areas.
f) BAKELITE: A kind of plastic insulator highly resistive of heat.
g) GASKET: It is used for the protection against leakage.
22
h) SILLICON RUBBER SHEET: It is used for dry type transformer.
The machines used for shaping the insulation material are:
a) Cylindrical machines
b) Circle cutting machine
c) Scarping machines
d) Punching press machines
e) Drilling machines
f) Guillotine machines
g) Bench saw (special for OD)
h) Jig saw (special for ID)
i) Circular saw
j) Lines in machines
The Cast Resin Dry Type Transformer (CRT) are also assembled here. As
we know the Dry Type transformer never uses any insulating liquid where
it’s winding with core be immerged. Rather windings with core are kept
within a sealed tank that is pressurized with air.
Cast Resin Dry Type Transformer (CRT) is used in the high moisture prone
areas. It is because of its primary and secondary windings are
encapsulated with epoxy resin. This encapsulation helps to prevent
moisture to penetrate to affect the winding material. Complete
protection is achieved by this cast resin encapsulation so that the
23
transformer can work without disruption in highly moisture prone area.
The insulation of these transformers are of insulation class F (90 C
temperature rise). Advantages of these transformers are:
1) Better over load capacity.
2) Low partial discharge along with low loss. Hence efficiency is very
good.
3) As it is with non-inflammable winding insulation, it offers zero risk to
fire hazard. So it is suitable for indoor installation.
4) Can be fitted outdoor in IP 45 enclosure.
5) This transformer is non hygroscopic.
1.3.8 BAY-8:
It is the Instrument transformer and ESP transformer manufacturing
section.
Instrument Transformer:
These are used for measurement. They are high accuracy class electrical
devices used to isolate or transform voltage or current levels. The most
common usage of instrument transformers is to operate instruments or
metering from high voltage or high current levels, safely isolating
secondary control circuitry from the high voltages or currents. The
primary winding of transformer is connected to the high voltage or
current circuit, and meter or relay is connected to secondary side. They
are used in AC systems for measuring of current, voltages and energy and
can also be used for measuring power factor, frequency and for indication
of synchronism. They find application in protection of power systems &
24
for the operation of over voltage, over current, earth fault and various
others types of relays. Also be used as an isolation transformer so that
secondary quantities may be used in phase shifting without affecting
other primary connected devices.
They are of two types:
1. Current Transformer: It is a series connected type of instrument
transformer. They are designed to present negligible load to the
supply being measured and have an accurate current ratio and phase
relationship to enable accurate secondary connected metering.
The CT is typically described by its current ratio from primary to
secondary. Standard secondary current ratings are 5 amperes or 1
ampere, compatible with standard measuring instruments.
25
N p Is
=
Ns Ip
1.3.9 BAY-9:
In this bay power transformer are assembled. After taking different input
from different bays 0-9, assembly is done. Power transformer is used to
step down voltages at generation and sub stations. There are various
ratings: 11KV, 22Kv manufactured, they are:
a) Generator Transformer System
b) Auto Transformer
26
A transformer in a process of assembling is called job. The design of the
transformer is done by the design department and is unique of each job;
depends upon the requirement of the customer. The design department
provides drawing to the assembly shop, which assembles it accordingly.
The steps involved in assembly are:
Core building
Core lifting
Unlacing & Core coil assembly
Relacing & End frame mounting
H.V.&L.V. terminal gear
Vapor phasing & oil soaking
Final serving and taking
Case fitting
2 Locomotive section:
This section was introduced in 1985 and in 1987-88 they started
manufacturing diesel shunting locomotives and AC/DC locomotives.
Similar to Transformer section, Locomotive section also has three main
departments.
27
After delivery regarding faults, this department does failures and
maintenance. All such snags are reported to them and they forward the
information to the concerning department.
The work of TRC & LMC is similar.
The main work of the LMC is classified as:
Tenders and Notices.
Interaction with design department.
Place of the work.
Approximate cost of the work.
Earnest money.
Place and time where contract documents can be seen.
Place and time where tender documents can be obtained.
Time up to which the documents will be sold.
Amount if any to be paid for such documents.
Place, date and time when tenders are to be submitted and are to be
opened.
Any other information relevant in tender notices.
28
The designs & drawings that are provided to the LMM units for
manufacturing a locomotive are made by this department along with
given time to make that part. They also provide the necessary guidelines
to the workers to make the product effectively if necessary.
29
Driving cab at both ends
Corridors on both sides for maintenance
All pneumatic valves at one place
Automatic wheel slip detection & correction
Multiple unit operation up to three locomotives
Fault display on driver’s desk
VCB in AC circuit
Air & vacuum brakes
30
FRP control desk
VCB in AC circuit
Air & vacuum brakes
Air dryer for brake system
3 Store:
All of the raw material that is imported here is kept in a place which is
given the name of store. The details related to the materials, company
which provide that materials etc. are also with the staff that is assigned in
this section. The details of the stock left in the store, how much raw
material they have to import, its cost, time etc. is handled by the staff in
this section. The commercial details related to the materials in store or to
be ordered is done by the commercial department.
4 Testing:
Testing is a way to ensure that the product that has been manufactured
meets the specified requirements or not. Various tests related to the
transformers that are manufactured here are carried in the respective
manufacturing section.
The materials that are used to manufacture the products are also tested
before putting into use in the testing lab.
31
The tests which are done at various production stages are also carried out
in the respective manufacturing section.
5 Quality Check:
There is also a separate department which ensures the quality of the
product under manufacturing or manufactured. They keep on regular
check on the quality of the various parts under process. Also the quality
of the material that is imported in the company is ensured by this
department.
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Power Transformer
Power transformers are used in generating stations or substations at each
end of power transmission line for stepping up or stepping down the
voltage. They are put in operations during load periods and are
disconnected during light periods. They are designed to have maximum
efficiency at or near full load. Power transformers are designed to have
considerably greater leakage reactance. For power transformers the
voltage regulation is less important than the current limiting effect of
higher leakage reactance.
Two winding transformers are generally used where ratio of high voltage
and low voltage is greater than 2. It is cost effective to use auto
transformer where the ratio between high voltage and low voltage is less
than 2. Again a single unit three phase transformer is more cost effective
than a bank of three single phase transformers unit in a three phase
system. But a single three phase transformer unit is a bit difficult to
transport and have to be removed from service entirely if one of the
phase winding breaks down.
35
1 Assembly of Power Transformer
5.1Core of Transformer: A brief idea
5.1.1 Purpose of core
In an electrical transformer, there are primary, secondary and may be
tertiary windings. The performance of a transformer mainly depends
upon the flux linkages between these windings. For efficient flux linking
between these windings, one low reluctance magnetic path common to
all windings should be provided in the transformer. This low reluctance
magnetic path in transformer is known as core of transformer.
37
5.1.3 Influence of diameter of core
Let us consider, the diameter of transformer core be ′D′ Then, cross-
sectional area of the core,
π D2
A=
4
E=4.44 Bm Af
40
Oil Ducts
In addition to that, clamp plates made of steel are needed on either sides
of the core to clamp the lamination. The steel sheet lamination blocks, oil
ducts, and clamping plates, all should lie within the peripheral of
optimum core circle. The net sectional area is calculated from the
dimensions of various packets and allowance is made for the space lost
between lamination (known as stacking factor) for which steel sheet of
0.28 mm thickness with insulation coating is approximately 0.96. Area is
also deducted for oil ducts.
The ratio of net cross sectional area of core to the gross cross - sectional
area inside the imaginary peripheral circle is known as Utilization factor of
transformer core. Increasing numbers of steps improve the Utilization
factor but at the same time, it increases manufacturing cost. Optimum
numbers of steps are between 6 (for smaller diameter) to 15 (larger
diameter).
41
5.1.5 Corner Jointing of Limbs with Yokes
Core losses in transformer happen mainly due to,
1. Magnetic flux flow along the direction of the grain orientation,
2. Magnetic flux flow perpendicular to the direction of the grain
orientation, this is also known as cross grain iron losses. The cross grain
loss mainly occurs in the zones of corner jointing of limbs with yokes and
it can be controlled to some extent by applying special corner jointing
techniques.
There are normally two types of joints used in transformer core
1. Interleaved joints
2. Mitred joints
Interleaved Joints
Interleaved joint in transformer core is the simplest form of joints. This
joint is shown in the figure. The flux leaves and enters at the joint
perpendicular to grain orientation.
Fig. b
42
Hence cross grain losses are high in this type of joints. But considering the
low manufacturing cost, it is preferable to use in small rating transformer.
Mitred Joints
Here the lamination's are cut at 45°. The limbs and yoke lamination edges
are placed face to face at the Mitred joints in transformer core. Here the
flux enters and leaves the lamination, gets smooth path in the direction of
its flow. Hence, cross grain loss is minimum here.
Fig. c
Yoke
44
The cuttings shown in Fig.d are stacked together to make a core of
transformer of cross-section as shown in Fig.a and the forming a shape of
three limb core as shown in Fig.c.
During core manufacturing in factory some factors are taken into
consideration,
1. Higher reliability.
2. Reduction in iron loss in transformer and magnetizing current.
3. Lowering material cost and labor cost.
4. Abatement of noise levels.
Quality checking is necessary at every step of manufacturing to ensure
quality and reliability. The lamination should be properly checked and
inspected visually, rusty and bend lamination should be rejected. For
reducing the transformer noises, the lamination should be tightly
clamped together and punch holes should be avoided as far as possible to
minimize cross flux iron losses. The air gap at the joint of limbs and yokes
should be reduced as much as possible for allowing maximum smooth
conducting paths for magnetizing current.
45
The picture shows the cuttings of CRGOS in different dimensions and how
they are put for making the core. These sheets are stacked to make the
core of transformer using end frames and are tightly held by fitting
circular rods of Permawood in the steps formed during stacking and then
wound using the tape.
46
A core after stacking and clamping is shown in the picture.
5.2Coil winding
The winding consist of the current carrying conductors wound around the
sections of the core, and these must be properly insulated, supported and
cooled to withstand operational and test conditions. Copper is primarily
used as conductors in transformers windings here. The copper which is
used is paper covered rectangular copper conductor.
Types of winding:
Reverse section winding.
Helical winding.
Spiral winding.
47
Interleaved winding.
Half sectional winding.
1. R-S Winding:
In this winding one section is given the reverse winding while one
section is given the forward winding. This can be manufactured is
various sizes say five parallel or two parallel conductors as suggested by
the designer. The layer depth or LD of the winding is defined as the
number of turns to the number of segments available in the section.
Generally one to eight numbers of conductors are used in this kind of
winding.
2. Helical Winding:
It is winded in shape of a spring. Here the numbers of conductor are
more in numbers than others and all are insulated from each other in
order to reduce EDDY current losses. Transposition in this kind of
winding is done to make the conductors equal in length so that no
possibility of spark should be there due to differences of voltages
induced due to length of conductors. Two kinds of transposition are
usually done in this kind of winding:
1) Section wise transpose
2) Three numbers of transpose are provided in between
conductor turns
3. Spiral Winding:
This is the simplest kind of winding the conductors are simply wounded
on the base. The side from where the winding is started is known as
the start lead and where it is finished is known as the finish lead.
48
4. Half sectional Winding:
These kind of coil can be classified on the basis of winding direction if
the winding is started by rotation of conductors in anticlockwise
direction it is known as standard half sectional coil whereas if the
rotation is clock wise it is termed as non-standard half sectional coil.
The brazing leads required in some cases of the transformer are also
provided in this kind of the winding.
5. Interleaved Winding:
In some cases the conductors are wounded in such a fashion that the
interleaved winding current rotates in same conductor. When
interleaved the number of conductor gets doubled than initial number.
After that section is made the conductors are connected using entries.
6. Composite Winding:
In this kind of winding more than one conductor is winded with
other on the same machine. These windings are generally used for
the purpose of tapped coils.
Terms connected with the windings are:
1. ID: This is known as the inner depth or diameter of the coil. This is
basically the width of the base on which the conductors are
wounded.
2. OD: This is known as the outer depth or diameter of the coil. This is
basically the width of the wounded conductors starting from first
turn to the last turn.
3. MD: This is known as the mould diameter and same as the ID or
inner depth of the coil.
49
4. CD: This is known as the coil dimension and is basically taken as the
length measured form starting lead point to the finishing lead point.
The coils that are presently used for the power transformer are reverse
section wound.
Fig. e
50
The main purpose of unlacing the core is to remove the top end frame
and yoke of the core. An unlaced core is shown in the picture below:
51
The coils are that present in the power transformer are also insulated
from one another using press board and blocks of wood. The picture
below shows the insulation between two coils. The press board is also
wound by using tapes.
52
5.5Relacing of Core:
After the coils have been mounted on the core the top yoke is again
attached to the rest of the core, this process is known as the relacing of
the core. Before relacing top insulation to separate the coils from the top
yoke is also inserted. The sheets are attached one by one or in packets to
the core limbs in erect position.
The copper leads or bus bars used during TG assembly are insulated
using Crepe paper.
The conductors to the tap changer can be observed in the H.V. marked
in numbers these are then connected to the tap changer. All the leads
are properly brazed for accurate connections so that same amount of
current flows through each conductor and the ratio can be achieved. In
L.V. side the bottom leads of the L.V. coils are joined together to form
neutral. Whereas the top lead positions are taken out for respective 3-
Ø connection.
5.8Tanking:
The tank gives mechanical protection to the windings and core and also
provide weather protection. It holds the insulating oil that insulates the
windings and acts as a cooling agent. The tanks are made of steel. In
tanking the assembled job after terminal gear assembly and processing is
put into the tank and oil is filled.
The tank cover is designed to prevent water collection and the raised
flanges are provided to prevent water entry.
56
little bit shorter than 90°.
Tangent of the angle by which it is short of 90° is called dielectric
dissipation factor or simply tan delta of transformer oil. More clearly, the
leakage current through an insulation does have two component one is
capacitive or reactive and other one is resistive or active. Again it is clear
from above diagram, value of ′δ′ which is also known as loss angle, is
smaller, means resistive component of the current IR is smaller which
indicates high resistive property of the insulating material. High resistive
insulation is good insulator. Hence it is desirable to have loss angle as
small as possible. So we should try to keep the value of tanδ as small as
possible. High value of this tanδ is an indication of presence of
contaminants in transformer oil. Hence there is a clear relationship
between tanδ and resistivity of insulating oil. If resistivity of the insulating
oil is decreased, the value of tan-delta increases and vice versa. So both
resistivity test and tan delta test of transformer oil are not normally
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required for same piece of insulator or insulating oil. In one sentence it
can be said that, tanδ is measure of imperfection of dielectric nature of
insulation materials like oil.
5.9Case Fitting:
After tanking the accessories of the transformer are fixed to give the final
touch to the job. Also the terminals for low, high and tap changing
terminals are brought out of the tank by using bushings.
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5.9.3 Bushings:
A bushing is a mean of bringing an electrical connection from the inside
to the outside of the tank. It provides the necessary insulation between
the winding electrical connection and enabling the necessary vacuum to
be drawn for the purpose of oil impregnation of the windings. It must
ensure freedom from leaks during the operating lifetime of the
transformer and be capable of maintaining electrical insulation under all
condition such as rain, ice and fog and has to provide the required
current-carrying path with an acceptable temperature rise. There is a
current carrying stem usually of copper and the insulation is provided by
a combination of the porcelain shell and the transformer oil.
Before fitting the bushings on the transformer, they should be checked for
any damage or crack. Bushings are normally delivered in complete
assembled form.
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5.9.4 Motor Driving Unit
The main function of this unit is to operate the tap changer. Using this
unit the tap changer can be operated manually and required voltage can
be achieved.
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damages of upper diaphragm. Near the lower end, a small oil level
indicator is provided to lower diaphragm ruptures; transformer oil rises in
the vent pipe and is visible through the indicator indicating the failure of
the lower diaphragm. If even after brushing the lower diaphragm, there is
enough pressure and is not reduced, the upper diaphragm then bursts
out to give way to release the inside pressure of transformer tank by
thronging out oil and gases. In this way, explosion vent of transformer
prevents mechanical damage to the transformer tank. Sometimes, upper
portion of conservator tank is connected with explosion vent with an
equalizer pipe with or without a valve.
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5.9.7 Nitrogen in Transformers
Oil filled Transformers usually have a conservator which maintains the
level of oil. The conservator has a layer of air on top of the oil. This air
communicates with the atmosphere through a breather containing a
desiccant, usually, silica gel.
In some transformers, the tank of the transformer is filled with a layer of
nitrogen above the oil in which the windings and the core are immersed.
Nitrogen, being an inert gas, reduces the risk of a fire hazard. It also
protects the transformer oil and the transformer insulation from reacting
with oxygen in the air and deteriorating.
In transformers containing nitrogen, the nitrogen is led into the space
above the conservator through a pressure reducing valve. When the oil
level in the transformer rises and the transformer breathes out, the
nitrogen inside is released into the atmosphere. When the oil levels fall
due to a reduction in ambient temperature or the load, fresh nitrogen is
released into the conservator through the cylinder and the valves.
After all the steps a power transformer looks like as shown in the picture
below:
After the assembly of the power transformer final testing is carried out to
ensure proper working of the transformer, some of the tests are given
below:
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6 Final Testing
6.1Transformer Ratio Test
The performance of a transformer largely depends upon perfection of
specific turns or voltage ratio of transformer. So transformer ratio test is
an essential type test of transformer. This test also performed as routine
test of transformer. So for ensuring proper performance of electrical
power transformer, voltage and turn ratio test of transformer one of the
vital tests.
The procedure of transformer ratio test is simple. We just apply three
phase 415 V supply to HV winding, with keeping LV winding open. Then
we measure the induced voltages at HV and LV terminals of transformer
to find out actual voltage ratio of transformer. We repeat the test for all
tap position separately.
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6.4Temperature Rise Test of Transformer
Temperature rise test of transformer is included in type test of
transformer. In this test we check whether the temperature rising limit of
the transformer winding and oil as per specification or not. In this type
test of transformer, we have to check oil temperature rise as well as
winding temperature rise limits of an electrical transformer.
6.7Impulse test
Lighting is a common phenomenon in transmission lines because of their
tall height. This lightning stroke on the line conductor causes impulse
voltage. The terminal equipment of transmission line such as power
transformer then experiences this lightning impulse voltages. Again
during all kind of online switching operation in the system, there will be
switching impulses occur in the network. The magnitude of the switching
impulses may be about 3.5 times the system voltage. Insulation is one of
the most important constituents of a transformer. Any weakness in the
insulation may cause failure of transformer. To ensure the effectiveness of
the insulation system of a transformer, it must confirms the dielectric test.
But the power frequency withstand test alone cannot be adequate to
demonstrate the dielectric strength of a transformer. That is why impulse
test of transformer performed on it.
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Generally there are two similar higher readings on two outer limb phases
on transformer core and one lower reading on the Centre limb phase, in
case of three phase transformers. An agreement to within 30% of the
measured exciting current with the previous test is usually considered
satisfactory. If the measured exciting current value is 50 times higher than
the value measured during factory test, there is likelihood of a fault in the
winding which needs further analysis.
7 Dispatch
After successful completion of testing, transformer is handed over to
dispatch sections.
At this stage after checking oil leakage, dismantling of all bushings, turrets
etc. and covered with the blanking plates and the tank is fitted with
nitrogen gas and then the transformer is dispatched to the concerned
site.
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Conclusion
This report gives the idea about the various departments of BHEL, Jhansi.
The assembly of the power transformer, its parts and their working and
some of its test are also given in this report.
This report can provide a general idea of how a power transformer is
manufactured.
BHEL, Jhansi although a smaller unit in comparison to other units of BHEL,
is a very productive one with the manufacturing of the electric
locomotives, power transformers etc.
The work load here can be accessed from the fact that the order of the
locomotives has forced the company to shift its Bus Duct section to other
unit of BHEL.
References:
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Guidance from the technical staff and working staff of BHEL,
Jhansi
Ashfaq Hussain, Electric Machines, Second Edition, Dhanpat
Rai& Co.
J.B. Gupta, Electrical Machines
www.bhel.com
www.wikipedia.org
www.bheljhs.com
www.eletrical4u.com
www.quora.com
electrical-engineering-portal.com
answers.yahoo.com
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