Acknowledgement

The extensive training program at BHARAT HEAVY ELECTRICALS LIMITED

(BHEL),Bhopal was a great opportunity and an exceptional learning experience for
me. It is first hands on experience and an exposure of practical world.

I got opportunity to work under the esteemed supervision of Mr.P.K.JAISWAL,

Manager (TXM). It was great privilege for me to work under him. I am thankful to
him for his extremely patient gesture, to make training program fruitful for me and
for rendering every possible help to carry out this research project.

I offer my gratitude to the management and staff that have spent their precious
time, expressed keen interest and given continued encouragement throughout the
study and enabled the successful completion of my practical at BHEL, Bhopal.

I am indebted to my parents, teachers and friends who helped and encouraged me

to work hard, move ahead and inspired me with words. Their blessings made this
work possible.

Siddharth Trivedi

1
CERTIFICATE

This is to certify that Mr.Siddharth Trivedi from

LNCT&S ,Bhopal has completed her Vocational Training
at BHEL, Bhopal from 7th June, 2018 to 4thJuly, 2018.

I have found her sincere, hardworking and technically

sound. she has worked well. I take this opportunity to
wish her best for the future.

PROJECT GUIDE:
Mr.P.K. JAISWAL
Manager (TXM)

2
Contents:

 Acknowledgement
 Company Overview
 Product Profile
 Bharat Heavy Electricals Limited (BHEL), Bhopal
 Various Divisions at BHEL Bhopal
 Transformer:
 Windings
 Material Used For Winding
 Magnetic Circuit
 Core:
 Short Circuit Resistance
 Tank
 Transformer Cooling
 Cooling System:
 Processing
 Accessories
 Oltc
 Transformer Fittings
 Transformer Testing:
 Major Landmarks / In house R&D Projects
 Erection At Site: Inspection
 Oil Filling
 References

3
BHARAT HEAVY ELECTRICALS LIMITED

BHEL is the largest engineering and manufacturing enterprise in India in the energy-
related/infrastructure sector, today. BHEL was established more than 40 years ago, ushering in
the indigenous Heavy Electrical Equipment industry in India - a dream that has been more than
realized with a well-recognized track record of performance. The company has been earning
profits continuously since 1971-72 and paying dividends since 1976-77.

BHEL manufactures over 180 products under 30 major product groups and caters to core sectors
of the Indian Economy viz., Power Generation & Transmission, Industry, Transportation,
Renewable Energy, etc. The wide network of BHEL's 14 manufacturing divisions, four Power
Sector regional centers, over 100 project sites, eight service centers, 18 regional offices and one
subsidiary enables the Company to promptly serve its customers and provide them with suitable
products, systems and services -- efficiently and at competitive prices.

BHEL has acquired certifications to Quality Management Systems (ISO 9001), Environmental
Management Systems (ISO 14001) and Occupational Health & Safety Management Systems
(OHSAS 18001) and is also well on its journey towards Total Quality Management.

 BHEL has installed equipment for over 90,000 MW of power generation -- for Utilities,
Captive and Industrial users.
 Supplied over 2,25,000 MVA transformer capacity and other equipment operating in
Transmission & Distribution network up to 400 kV (AC & DC).
 Supplied over 25,000 Motors with Drive Control System to Power projects,
Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc.
 Supplied Traction electrics and AC/DC locos to power over 12,000 kms Railway
network.
 Supplied over one million Valves to Power Plants and other Industries.

4
BHEL's operations are organized around three business sectors, namely Power, Industry -
including Transmission, Transportation and Renewable Energy - and Overseas Business. This
enables BHEL to have a strong customer orientation, to be sensitive to his needs and respond
quickly to the changes in the market.

BHEL's vision is to become a world-class engineering enterprise, committed to enhancing

stakeholder value. The company is striving to give shape to its aspirations and fulfill the
expectations of the country to become a global player.

The greatest strength of BHEL is its highly skilled and committed 42,600 employees. Every
employee is given an equal opportunity to develop himself and grow in his career. Continuous
training and retraining, career planning, a positive work culture and participative style of
management all these have engendered development of a committed and motivated workforce
setting new benchmarks in terms of productivity, quality and responsiveness.

Product Profile
With an export presence in more than 60 countries, BHEL is truly India’s industrial ambassador
to the world. This list is intended as a general guide and does not represent all of BHEL's
products and systems.

Thermal Power Plants

 Steam turbines and generators of up to 500MW capacity for utility and combined-cycle
applications; capability to manufacture steam turbines with super critical steam cycle
parameters and matching generator up to 1000 MW unit size.

Gas based Power Plants

 Gas turbines of up to 260MW (ISO) rating.
 Gas turbine based co-generation and combined-cycle systems for industry and utility
applications.

5
Hydro Power Plants
 Custom-built conventional hydro turbines of Kaplan, Francis and Pelton types with
matching generators, pump turbines with matching motor-generators. Mini/micro hydro
sets.
 Spherical, butterfly and rotary valves and auxiliaries for hydro station

DG Power Plants
 HSD, LDO, FO, LSHS, natural-gas/biogas based diesel power plants, unit rating up to
20MW and voltage up to 11kV, for emergency, peaking as well as base load operations
on turnkey basis.

Industrial Sets
 Industrial turbo-sets of ratings from 1.5 to 120MW.
 Gas turbines land matching generators ranging from 3 to 260MW (ISO) rating.
 Industrial stream turbines and gas turbines for drive applications and co-generation
applications.

Boilers and Auxiliaries

 Steam generators for utilities, ranging from 30 to 500MW capacity, using coal, lignite,
oil, natural gas or a combination of these fuels: capability to manufacture boilers with
super critical parameters up to 1000 MW unit size.
 Steam generators for industrial applications, ranging from 40 to 450t/hour capacity using
coal, natural gas, industrial gases, biomass, lignite, oil, biogases or a combination of these
fuels.
 Pulverized fuel fired boilers.
 Stoker boilers.
 Pressure vessels.

Heat Exchangers and Pressure Vessels

 Air-cooled heat exchangers.
 Surface condensers.
 Steam jet air ejectors.

6
  LPG/propane storage bullets.
 Feed water heaters.

Power Station Control Equipment

 Microprocessor-based distributed digital control systems.
 Sub-station controls with SCADA.
 Static excitation equipment/automatic voltage regulator.
 Electro-hydraulic governor control.
 Turbine supervisory system and control.
 Controls for electrostatic precipitators.
 Controls for HP/LP bypass valves.

Switchgears
 Switchgear of the various types for indoor and outdoor applications and voltage ratings
up to 400 kV.
 Minimum oil circuit breakers (66K – 132kV).
 SF6 circuit breakers (132 kV – 400 kV).
 Vacuum circuit breakers (3.3 kV – 33 kV).
 Gas insulated switchgears (36 kV).

Transformers
 Power transformers for voltage up to 400 kV.
 HVDC transformers and reactors up to + 500 kV rating.
 Series and shunt reactors of up to 400 kV rating.
 Current transformers up to 400 kV.
 Electro-magnetic voltage transformers up to 220 kV.
 Capacitor voltage transformers up to 400 kV.
 Special transformers: earthing; furnace; rectifier; electrostatic precipitator; freight loco
and AC EMU and traction transformers.

7
Insulators
 Disc/suspension insulators for AC/DC applications, ranging from 45 to 400 km electro-
mechanical strength, for clean and pollute atmospheres.
 Pin insulators of up to 33 kV.
 Hollow porcelains of up to 400 kV.
 Solid core insulators of 25 kV rating (both porcelain and hybrid) for railways.
 Disc insulators for 800 kV AC and HVDC transmission lines (BHEL is the first Indian
manufacturer to supply such insulators).

Capacitors
 Power capacitors for industrial and power systems of up to 250 kVAr rating for
application up to 400 kV, Coupling/CVT capacitors for voltages up to 400 kV.
 Low Tension Thyristor Switched Capacitors (LTTSC) for dynamic power factor
correction.

Energy Meters
 Single Phase, Poly Phase and Special-purpose electro-mechanical and electrical meters.

8
Bharat Heavy Electricals Limited (BHEL), Bhopal

Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals Limited, the
largest engineering and manufacturing enterprise in India in the energy-related and infrastructure
sector, today. With technical assistance from Associated Electricals (India) Ltd., a UK based
company; it came into existence on 29th of August, 1956. Pt. Jawaharlal Nehru, first Prime
minister of India dedicated this plant to the nation on 6th of November, 1960.

BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving towards
excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat Exchanger
Division is accredited with ASME ‘U’ Stamp. BHEL Bhopal has its own Laboratories for
material testing and instrument calibration which are accredited with ISO 17025 by NABL. The
Hydro Laboratory, Ultra High Voltage laboratory and Centre for Electric Transportation are the
only laboratory of it’s in this part of the world.

BHEL Bhopal's strength is its employees. The company continuously invests in Human
Resources and pays utmost attention to their needs. The plant's Township, well known for its
greenery is spread over an area of around 20 sqkms. and provides all facilities to the residents
like, parks, community halls, library, shopping centers, banks, post offices etc. Besides, free
health services are extended to all the employees through Kasturba Hospital and chain of
dispensaries.

Various Divisions at BHEL Bhopal

 Industrial Machines
 Transportation Equipment
 Hydro Turbines and Generators
 Hydro Generators
 Heat Exchangers
 Excitation Control Equipment

9
 Steam Turbines
 Fabrication
 Coil & Insulation
 Casting
 Stamping
 Tool & Gauge
 Transformer
 Switchgear
 On-Load Tap Changer
 Large Current Rectifiers
 Control & Relay Panels
 Hydro Power Plant
 Thermal Power Stations
 Works Engineering & Services

10
11
TRANSFORMER:
Definition: A transformer is a static piece of apparatus used for the transferring power from one
circuit to the other without change in frequency. It can raise or lower the voltage with a
corresponding decrease or increase in current.

Voltage transformation ratio:


E1  4.44  f  N1  m
E2  4.44  f  N 2  m

E1 N1


E2 N 2

WINDINGS:
 Primary winding
 Secondary winding
 Linkage of the two by mutual inductance

Low Voltage Winding Design:

 Since voltage is less, hence turns will also be less.

 Phase current = MVA/( 3 *line voltage in KV) if winding is star connected

 Phase current = MVA/(3*line voltage in KV) if winding is delta connected

This indicates low voltage winding shall be high.

High voltage winding:

 Large no. of turns

 Less current
 Disc coils are the best choice for the HV windings where a single disc can have turns as
high as 25 no.

Transformer winding is cylindrical and arranged concentrically. This design offers substantial
advantages like:

 Simplicity and elimination of weak insulation points by means of symmetrical layout.

12
  Great mechanical resistance to short circuit stresses.
 Free oil flow through cooling channels.
 The rating and connection of the winding largely determine the choice of the type of
winding

The following four types of windings are generally used:

 Helical winding.
 Spiral winding.
 Continuous disc section winding.
 Interleaved disc winding.

Helicalwinding:

 To carry high current the area of cross section of the conductors should be high. This is
an accomplished by adopting more no. of conductors per turn.
 Helical winding which is spring like, suits most for the LV windings.

This is generally used for low voltage windings and consists of a number of parallel conductors
simultaneously wound on an insulating cylinder of high mechanical strength. Where current is
very high, the conductors are transposed to ensure equal current distribution in all strands,
thereby reducing stray copper losses to a minimum. To provide adequate cooling, axial and
radial ducts are provided by spacer blocks.

Spiral winding:

The spiral windings are generally used for voltages upto33 KV. These are essentially same as
helical windings, except that turns are not separated by radial spacing blocks.

Continuous disc section winding:

This winding is used for voltages between 33 KV and 132 KV, the winding is generally split into
a number o separate coils, in order to limit the voltage per coil.

These coils are made up of one or several flat conductors wound in spiral form. These are
stacked one above the other and connected in series by cross over s made alternately on their
inner and outer sides, so that the windings are continuous without any joints between coils.

Such a winding is made in the simplest form proportioning the insulation at each point to suit the
power frequency and surge voltage stresses. For system voltages above 66 KV, stress rings are
usually incorporated to modify the stresses at the ends of the winding.

To ensure adequate cooling, oil ducts are provided by vertical pressboards spacing strips and
horizontal radial spacing blocks between the sections.

13
Interleaved disc winding:

For EHV windings, interleaved disc winding is commonly used. By properly interleaving the
turns within a pair of discs, the series capacitance of winding can be increased many times. This
results in nearly uniform voltage distribution under impulse conditions. Crossovers are made at
the inside of the disc pair and joints are made near the outside. More often partially interleaved
disc coil is used where only a part winding is interleaved and balance portion is continuous disc
construction.

MATERIAL USED FOR WINDING:

 P.I.C.C.
 C.T.C.
 Bunched P.I.C.C.
 Glued C.T.C.

MAGNETIC CIRCUIT:

 Magnetic circuit is formed by “CORE”.

 CORE is a three or five lagged.
 Coils which are of cylindrical shapes are assembled over the legs.

Other considerations:

 After designing the windings they are suitably placed over the core legs keeping in mind
the electrical stresses.
 Windings are designed for impulse withstand and short circuit forces also.
 This is followed by the cooling design.

14
CORE:

Any transformer consisting of core and windings core is the magnetic circuit through which flux
flows.

Materials used in core:

 The materials used for core making is low reluctance magnetic containing silicon. This is
called “CRGO” i.e. cold rolled grain oriented steel.
 The grain orientation is technology which ensures that the flux flow through the
laminations with minimum resistance, resulting in low core loss.

Type and construction of core:

There are following types of core available:-

 Two limb core

 Three limb core
 Five limb core
 Core with elliptical yoke section
 Core with flat yoke

Describing some terms in core construction:

Core diameter: diameter of the circle enclosing the steps of a core cross section. All the steps
are accommodated within this circle.

Frame size: the dimensions required to describe a core is called frame size. It comprises
description like core type, core diameter, legcentre and leg length.

Leg centre: this is the distance between the centerlines of main leg of a core.

Leg length: distance between top yoke level and bottom yoke level in a window is called leg
length.

Window: area enclosed by tops and bottom yoke and the main limbs. Yoke bolts: bolts used in
yokes to clamp the laminations together.

Top yoke level (TYL)/ bottom yoke level (BYL): edge of the top or bottom yoke in the
window.

Pin pad assembly: The arrangement to join clamps plates with end frames is called pin pad
assembly.

15
SHORT CIRCUIT RESISTANCE:

Circular coil offers the greatest resistance to the radial component of electromagnetic forces,
since this is the shape which any coil will tend to assume under short circuit stresses.

The longitudinal stresses are reduced by proper balancing of primary and secondary ampere-
turns, along the coil. In particular, the voltage adjustment taps are distributed so as to keep
imbalance of ampere-turns. Where large range of tappings are required, these are generally
arranged in a separate coil which is spread over the whole length of the coil stack, in order to
preserve magnetic balance between the windings as far as practicable, and to minimise axial
stresses under fault conditions.

TANK:

Tanks are fabricated from mild steel plates, electrically welded and are shot-blasted, inside as
well as outside to remove any scales before painting. The inner surface is coated with suitable oil
resistant paint whereas the outer surface is painted with high quality anticorrosive paint system
comprising of four coats.

Tanks are designed and tested to withstand appropriate vaccum and pressure. For special
designs, the mechanical stresses are analysed by finite element method. The welding are checked
by ultrasonic/dye penetration method for any defects.

The tank fabrication shop is fully equipped to make tanks of any shape and of the larget sizes,
including bell type construction. Thus construction allows access to core and winding for
maintenance purposes.

16
Purpose of transformer tank:

Transformers tank is an enclosure which contains inside it the live parts such as core and
winding assembly, electrical connections and insulating oil.

Most basic classification:

 Conventional
 Bell type

Conventional tank: A tank in which the cover is flat and the tank to cover junction is at the top
of the tank.

Bell type tank: a tank in which the cover is not flat in shape and the tank and cover junction is
near the bottom of the tank.

Thus the tank has got two parts “TOP TANK & BOTTOM TANK”.

Tank Base:

Base can be with or without rollers. Rollers of four types and are of standard design.skid base
This base is suitable for placement on the plinth.

TRANSFORMER COOLING:

When the transformer is in service the windings get heated up. In oil filled power transformer oil
is the cooling medium for windings. Oil is in turn cooled by means of radiators/integral coolers
with water/air as cooling medium.

Types of cooling:

 ONAN cooling
 ONAF cooling
 OFAF cooling

ONAN cooling:

Oil flows is through natural convection. Air flow s also natural (not forced).Cooling equipments
used radiators.

ONAF Cooling:

The oil flow is through natural convection.Air flow is not natural but it is forced. For cooling,
equipments used are:radiators and fans,ONAF coolers

OFAF Cooling:

17
Oil flow is forced by means of inline oil pumps. Air flow is forced by means of fans/blowers.
Cooling equipments used: Radiators,fans and pumps or integral OFAF coolers.

COOLING SYSTEM:

Natural and Air blast cooling:

Detachable radiators are used to provide adequate cooling surface mounted directly on the tank
side or built up in one or two banks placed adjacent to the transformer and connected to it by
pipe work. The radiator element is made from specially treated sheet steel plates. Two rolled and
pressed plates are welded together along the outer edges and along the troughs between flutes. A
number of such elements are welded into a mild steel header.

Water cooling:

The water cooling is usually of condenser type. Top oil pumped around a set of tubes through
which cooling water circulates. This type of cooling reduces the space requirement considerably,
and is recommended specially for generator transformer where plenty of cooling water is
available. To prevent any possible leakage of water into the transformer oil, oil pressure is
always maintained higher than the circulating water pressure.

Forced oil cooling:

Hot oil from the top of the tank is pumped into a compact cooler with built-in fans, and returned
to the tank at the bottom. Alternatively a pump can be introduced to force the oil circulation
between the top and bottom main radiator headers (where radiators are mounted in a separate
bank).

PROCESSING:

The quality of a transformer, and consequently its performance and life depends essentially on
the factory processing, which is carried out at various stages of manufacture.

All the coils are pre-shrunk before assembly. After the coils are assembled on the core, the whole
assembly is heated in an oven for extraction of moisture, and also the coils are reduced to proper
dimensions.

After final assembly, the core and coils are kept in their own tank, and the unit is placed in a
vacuum chamber for final drying. The chamber is heated up to about 100°C and a vacuum of
very high degree is maintained during dry –out. Sometimes vacuum drying is done by drawing
vacuum in its own tank and keeping the whole transformer inside an oven.

Besides this conventional method of drying, most modern Vapour Phase Drying method is used
alternatively.

18
Much importance is attached to proper dry-out, as otherwise coils would become loose in service
and may get distorted under short circuit conditions.

The oil is treated separately in a filtering and degerating plant, and is kept constantly under
vacuum at a temperature of 80°C, so that moisture-free degassed oil is always available. Ten
thousand gallons of oil can be treated in the plant at a time. Oil is tested for electrical strength,
and moisture content before the same is let into the transformer. The oil impregnation of winding
insulation is also done under high vacuum conditions. The dryness of insulation is measured in
terms of insulation resistance.

ACCESSORIES:

Oil conservator:

All power transformers are invariably provided with an expansion vessel called Conservator.
This is to take care of the changes in oil volume due to change in ambient temperature, or as a
consequence of changes in load on the transformer. The oil level conservator thus rises or falls,
resulting in phenomenon called ‘Breathing’.

The conservator is fitted with an oil preservation system called ‘Air cell’, which is a bag made of
nitrile rubber and it floats on the oil surface inside the conservator. The air cell inflates or
deflates as the oil level in the conservator falls or rises.

The above system prevents direct contact of transformer oil with atmospheric air and retards
oxidation and sludging, thereby greatly reducing the oil deterioration/maintenance problems at
site. Maintenance of the system is also negligible, since once in operation it generally needs no
attention other than routine visual inspection.

Oil level gauge:

A magnetic oil level is fitted to indicate oil level in the conservator, float of which is always
beneath the air cell. This gauge is also provided with a switch which gives alarm when the oil
level falls below the minimum oil level or when air cell is damaged and sinks.

Breather:

A breather is connected to the air cell and is used to dry the air that enters in the air cell when the
transformer breathes. The breather contains an absorbent material like silica gel for absorbing the
moisture present in the atmospheric air. Air entering the breather is first drawn through an oil
seal at the bottom, and passes upwards through the silica gel crystals to the connecting pipe at the
top of the air cell.During the upwards passage of air, any moisture present is absorbed by the dry
silica gel. The oil seal at the bottom ensures that the gel absorbs moisture only when the
transformer is breathing in.

19
Silica Gel Breathers:

Moisture is an enemy of transformer insulation system.

Whenever oil contracts transformer breaths in through breathers.

With air contains lot of moisture which is present in the air also go inside.

The silica gel present in the breathers absorb moisture and only dry air goes inside.

After a certain level of absorption the color of silica gel crystals change from blue to pink when
these particles should be recharged or replaced.

Temperature indicators:

Each transformer is provided with dial type thermometers for oil and winding temperature
indication. The bulb is placed in an oil filled pocket screwed into the transformer tank cover. The
pocket or the bellow for winding temperature indicator has a heating coil around it, temperature
indicator pocket/bellow which is fed by a CT provided on one of the transformer line terminals.
As such any changes in the load reflect in the heating of the winding temperature indicator
picket/bellow.

The expansion of the liquid in the bulb is transmitted through a capillary tube to an indicating
instrument. The dial type thermometer is also provided with mercury switches for alarm and trip
circuit operations in the event of excessive temperature rise and also for operation of cooling
fans and oil pump motors at certain preset temperatures. A potentiometer device can also be
provided for remote temperature indication.

Buchholz Relay:

When oil in the transformer tank expands some room for this expansion some room for this
expansion is required .This is provided by the conservator, which is a cylindrical vessel placed
above the transformer tank.Because of any internal fault heat is generated which decomposes oil
and insulation material resulting in the formation of gases. These gases rise up and while
approaching the conservator passes through the thebuchholz relay. buchholz relay is a
protective relay. When the accumulation is still higher then the float in the buchholz relay rises
activating a mercury switch which gives the alarm .when the gas accumulation is still higher
thenthe another float activates the trip switch disconnecting the transformer from the circuit.

The oil and gas actuated relay (buchholz) serves as a protection against any loss of oil, discharge
inside the tank and interturn short circuit and insulation defects. Indication for the above faults
are available from this relay even when the fault current is too small to operate the over current
and earth fault relays. This device is usually mounted in the connecting pipe between the highest
point in the transformer and the conservator. The device accommodates two floats, of which the

20
upper float is actuated by a build-up of gas and the lower float by a sudden oil surge. The
contacts for the first float normally give an alarm signal and those of the second, cause tripping.
Gas sample can be collected from the upper part of the device, and analysis of the gas gives an
indication as to the nature of fault.

Marshalling box:

A weather proof marshalling box is fitted on the side of the transformer tank or mounted
separately. This accommodates the oil and winding temperature indicators, starters etc for
various fan and pump motors, and terminal connectors from various alarm and trip circuits
provided in the transformer. A heater is provided inside the marshalling box to avoid any
condensation.

Pressure relief valve:

This is a spring loaded safety valve mounted on the tank cover for protection of transformers in
case of sudden over pressure. Valve diaphragm is sealed against gasket by springs. Valve
operation is effected when pressure inside the tank exceeds opening pressure established by
springs. The transformer pressure is then rapidly reduced to normal value and spring returns the
diaphragm to closed position.

Bushings:

Oil filled porcelain bushings are used for taking out the terminals for voltage up to a level of 33
KV. The bushing consists of a conductor within a porcelain jacket. For 52 KV and above,
condenser type bushings are used. The active part of these bushings consists of an Oil
impregnated paper (OIP) condenser core manufactured from superior grade craft paper wound on
aluminium tube. This bushing is voltage graded by suitably interposed aluminium foils forming
condenser layers. Thus the electrical stresses are controlled throughout the thickness and along
the surface avoiding highly stress concentrations.

The condenser core is assembled with a mounting flange and porcelain insulators at both outdoor
and oil immersed end. The wound core is vacuum dried and impregnated with high grade
degassed and dehydrated transformer oil. A prismatic or magnetic oil level gauge is provided to
indicate the level of oil in the bushings.

A self earthed test tap arrangement is provided on the flange which is used for measurement of
tan delta and capacitance of the bushings. Creepage distance suitable for polluted atmosphere is
also provided.

BHEL range of in-house manufacture of manufacture of bushings covers the complete

requirement up to 400 KV class and caters to requirement of both in-house manufactured
transformers as well as for other transformer manufactures.

21
Depending on specific requirement of customer, Oil filled/Air/Compound filled cable boxes are
also manufactured.

Types of overhead bushings:

High voltage, low voltage and in some cases third winding “tertiary” or “stabilising” leads are
brought out through bushings.they are called HV bushing,LV bushing and tertiary bushing.

These bushings can be mounted on the tank cover(or topmost horizontal plane in the tank) or in
some cases some bushings are mounted on vertical end walls

Tap changers:

OLTC: On Load Tap Changer

It’s purpose is t add or subract turns from the main coil.It is housed inside the transformer
tank(except ctroltc).these are the standard products and based on the variant in use their
dimensions are known is advance

The Tap Changers are used to vary the ratio of oil-immersed transformers under load.

The M-type tap changers comprise a diverter switch and a tap selector in a single column design.
The V-type tap changer works as a selector switch combining the features of a diverter switch
and a tap selector.

Few important features of M-type tap changer are:

 High speed transition resistor type diverter switch with arc extinction at the first current
zero.
 Three pole design for neutral application at 350A, 500A and 600A ratings for three phase
Y-connected windings.
 Three pole fully insulated design at 350A, 500A and 600A ratings for three phase Delta
or Auto connected windings.
 Single phase designs at 350A, 500A, 600A, 800A, 1200A, 1500A and 1800A ratings for
Auto connected or single phase transformers.
 Available with ±9, ±11, ±13, ±15, ±17 steps.
 Rapid tap change operation, low thermal stresses on the transition resistors.
 Tap selector gear with steady torque during the tap changer operation.
 Long contact life.
 Diverters switch contacts easy to replace.

Few important features of V-type tap changers are:

22
  High speed transition resistor type diverter switch with arc extinction at the first current
zero.
 Three pole design for neutral application at 200A, 350A and 500A ratings for three phase
Y-connected windings.
 Three pole fully insulated design at 200A, 350A and 500A ratings for three phase Delta
or Auto connected windings.
 Single pole designs at 200A, 350A and 700A ratings for single phase transformers.
 Available up to ±13 steps.
 The technical data of tap changer type M and V have been verified by type tests
according to IEC recommendations publ. 214 (1976).
 BHEL range of in-house manufacture of tap changer covers the complete requirement up
to 400 KV class transformers and caters to requirement of both, in-house manufactured
transformers as well as for other transformer manufacturers.

Control equipment:

The tap changer can be provided with local electrical, remote electrical independent and remote
electrical non-automatic/ automatic parallel operation. Outdoor weather- proof kiosk for
mounting of local electrical control equipment and indoor control cubicle for the mounting of the
remote control equipment can also be supplied.

TRANSFORMER FITTINGS:

 Cooling equipments
 Terminal arrangements
 Conservator
 O.L.T.C
 Instruments
 Breathers etc.

Radiators:

Radiators used in transformer cooling are of standard profile.They are normally described in
the following fashion:

For eg: 10-5or9-34-3000

10:no of radiators.

5 or 9: no of flutes in a radiator element.

32:no of elements in a radiator.

3000:distance between valve centers.

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Fans:

Cooling fans are normally classified on the basis of their size like 15,18, 24 or 36 inches.

Pumps:

Pumps are normally inline type. Its purpose is to pump oil through the transformer to create
forced flow of oil.

Mountings of radiators:

Radiators can be directly mounted on the tank wall,if the no. of radiators is not large. Radiators
can be mounted in a bank formation i.e. groups of radiators are mounted on headers and are
placed separately from tank.

Header:

Headers are pipes of square cross section. There shall be one top header and one bottom header
for a group of radiators. The header and radiator assembly is supported over “A” frames (named
so because of resemblance with alphabet “A”)

Header Pipe Work:

The headers are in turn joined with the tank where suitable valves for connecting pipe work are
provided. These pipes require pipe supports with suitable foundation.

Conservator Pipe Work:

It can be divided into parts:

 main conservator pipe work.

 auxiliary or oltc conservator pipe work

A conservator is a cyclinderical vessel which provides space for expansion of oil inside the
transformer or supplies oil to the transformer when transformer oil cools and contracts in
volume.

A conservator is always placed above the transformer.

When the conservator is used for the main transformer it is called main conservator and when it
is used for the oltc it is called auxiliary or oltc conservator.

Termination:

Transformers are connected in the system by any of the these methods as demanded by
customers .

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  Overhead bushings
 Cable boxes
 Bus duct
 A combination of above

Cable Boxes:

In sites where customers has laid cables instead of overhead conductors the
termination(connections) is through cable boxes Cable boxes are enclosed and are attached
externally to the transformer tanks. They can be on the LV walls, HV walls or on both LV and
HV walls. Similarly instead of walls they can be attached on the cover also

Bus duct:

Generator transformer primary is connected to the generator through bus ducts. For bus duct
connections bushings are brought out through cover or through independent/common turrets.
These bushings are enclosed circumferentially by hoods which turn receive the bus duct flange.

Combination of Termination Methods:

Termination of different windings can be through different combinations.

For example

 Hvbushing,lv cable box

 Hvbushing,lv bus duct.etc

M.O.G WITH LOLA:

It stands for magnetic oil gauge with low level alarm.

This is used with conservator.

Its purpose is to indicate the oil level in the conservator vessel and to give alarm when the oil
level falls below the threshold limit.

Oil Surge Relay:

This is similar to MOG but is used in on load tap changer oil compartment.

PRV:

Pressure relief wall,When transformer experiences excessive pressure due to extreme heating on
account of faulty operation or conditions then this valve saves the transformer by releasing the
excessive pressure and simultaneously disconnecting the transformer from the lines.

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This equipment is of spring loaded type.

OTI:

oil temperature indicator;This consists of a bulb dipped in a oil cup on the cover of the
transformer tank cover. This bulb is connected to the meter placed in the marshalling box meant
for housing the equipment electrical controls by means of a capillary.This indicates the
temperature of the top part of the transformer oil which is the hottest part.

WTI:

It is similar in construction to the OTI. This reads the temperature of the winding in an indirect
way. A current transformer injects current into the heating coil of the equipment giving the extra
temperature gradient over the top oil temperature which normally a winding is expected to have.

AIR CELL:

When transformer breathes in air oxygen also gets in touch with the oil.Oxygen oxides the
insulating oil and contaminate it in terms of the electrical properties.

 Air cell is rubber bag compatible with the transformer oil and is fitted inside the
transformer conservator.When oil in transformer contracts, it sucks air into the this bag
and when oil expands it expels air.Thus Air cells prevents atmospheric oxygen to come in
contact with the oil

TRANSFORMER TESTING:

Types of testings:

a)Routine tests

b)Type tests

Routine tests are conducted on each and every transformer of the lot/order.

Type tests are conducted on one transformer of a particular design and on successful passing of
this test the design of the transformer is said to be validated.

Routine Tests :

1) Ratio test

2) Vector group verification

3) Winding resistance

4) Core loss

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5) Load loss

6) Impedance measurement

7) Separate source voltage withstand test

8) Induced over voltage withstand test.

Type Tests:

1) Temperature rise test

2) Lightening impulse test

3) Vacuum and pressure test

Test Requirements:

In order to ensure the suitability of transformer for various possible transients/overvoltage of

system ,various national standards like is 2026(part-iii) and international standard like IEC
60076-3 define the test levels and test method requirement for different tests.

The major dielectric tests applicable for EHV class transformers are:

1)Lighting impulse withstand

2)Switching impulse withstand

3)Induced overvoltage with or without PD measurement.

4)Separate source voltage withstand test

Salient features:

In order to meet the country’s demand of testing facility at par with international standards, we
have established an Ultra High Voltage (UHV) laboratory, which is having certificate of
Accreditation as per ISO/IEC 17025/1999 standards from National Accreditation Board for
Testing and Calibration Laboratories (N.A.B.L.), Department of Science and Technology, India.
Testing of transformers of rating 315 MVA 3-phase; 200 MVA1-phase in 400 KV class, Shunt
reactors of rating 80 MVAR 3-phase in 400 KV class, ±500 KV DC 1-phase Converter
transformer, 800 KV Bushing and CVT have been satisfactorily established.

This UHV lab is having internal clear dimensions of 67 M (L) × 35 M (W) ×35 M (H) and is one
of the largest screened laboratories in the world, attached to a transformer manufacturing plant.

The major test equipments / facilities in our UHV lab are:

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  4 Million-volt, 400 KW Impulse Generator.
 500 Kilo-volt, 15 KW Impulse Generator.
 3.6 Million-volt, 400 pF Impulse voltage divider.
 3 Million-volt Multiple Chopping gap.
 1500 KVA, 1500 KV Cascade Connected testing transformer.
 160 MVA, 66/650 KV 3- phase testing transformer.
 3× 13.33 MVA, 11/90 KV, 1-phase transformers.
 3×3.33 KVAR, 11KV, 1-phase reactors.
 100 MVAR, 13-156 KV 3- phase Capacitor bank.
 1.2 Million-volt, 30 mA DC voltage generator.
 40 MVA, 0-11KV, 50 Hz, 3-phase MG set.
 9 MVA, 0-11 KV, 30-180 Hz, 3-phase MG set.
 7 MVA, 0-11 KV, 50 Hz, 3-phase MG set.
 2 MVA, 0-11 KV, 30-180 Hz, 3-phase MG set.
 Partial Discharge detector and RIV meter.
 2.5 M (dia) × 3.6 M (high) oil tank for Dielectric and Thermal Stability tests on
Bushings.
 800 KV, 71.5 pF SF6 filled standard capacitor.
 Frequency Response Analyzer equipment.

400 kV Bushing under test

MAJOR LANDMARKS / INHOUSE R&D PROJECTS:

 Complete range of products are type tested as per IS/IEC.

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  2 nos. 200 MVA, single phase, 400 KV Generator transformers tested for short circuit at
KEMA-Netherlands for M/s NTPC, India in 2002.
 186.2 MVA, 3- phase, 220 KV Generator transformer s tested for short circuit at KEMA-
Netherlands for M/s NTPC, India in 2000.
 167 MVA, 1-phase, 400 KV Auto transformers tested for short circuit at KEMA-
Netherlands for M/s NTPC, India in 2002.
 102 MVA, 1-phase, 400 KV Generator transformers tested for short circuit at KEMA-
Netherlands for M/s NTPC, India in1999.
 100 MVA, 3-phase, 400 KV Tie transformers tested for short circuit at KEMA-
Netherlands for M/s NTPC, India in 2003.

ERECTION AT SITE: INSPECTION; Make visual inspection for any transit damage .Check
nitrogen pressure. Check various accessories for any type of type of transit damage .Make
internal inspection of the transformer to the extent possible for any visible discrepancy.

OIL FILLING:

Before filling the oil into transformer check the oil carefully for

a) Break down voltage

b) Moisture content

c) Tan delta and capacitance

If the oil is not having the properties as recommended by the standards ,it must be filtered with
filters with built in heaters and vacuum pumps for improving the quality of oil.

For transformers dispatched gas filled , oil filling must always be done under vacuum.

Precautions during Oil Filling:

Keep the oil free from contamination. All equipments used for oil filling should be cleaned and
flushed with oil before filling. Flexible steel hose or good and known quality rubber hose alone
should be used. Transformer must be disconnected from the electricity from level in the tank is
lowered. Oil must not be emptied near naked lights as the vapours released is inflammable.

REFERENCES:
 Electrical Machinery by P.S. Bhimbra.
 BHEL Website – www.bhel.com .
 BHEL, Bhopal Website – www.bhelbhopal.com .
 Website – www.wikipedia.org .

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