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Distribution Transformer Manufacturing Process Manual PDF
Distribution Transformer Manufacturing Process Manual PDF
DISTRIBUTION TRANSFORMER
MANUFACTURING PROCESS MANUAL
Drafted by: Approved By:
1.0 Scope
This process manual describes the minimal requirement for any transformer
manufacturing plant intending to supply transformers to REA. The manual is designed to
assist REA deal with manufacturing plants that have established and certified
management systems addressing all aspects of Health, Safety, Environment and Quality
(HSEQ) either independently or jointly through an Integrated Management System
(IMS).
The manual defines the minimal processes required to ensure that the transformer
manufacturing plant adequately meets the customer requirements and applicable statutory
and regulatory requirements and aims to enhance customer satisfaction through effective
application of the system, including processes for continual improvement and assurance
of conformity to customer and regulatory requirements.
It is prepared based on the criteria governing ISO 9001:2008, ISO 14001:2004 and
OHSAS 18001:2007 International Standards.
2.0 Application
The process and system describe in this manual shall be applicable to all functional area
of the transformer manufacturing plant
3.0 Certification
The transformer manufacturing plant systems and processes shall be certified in
accordance with ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007
international standards as a minimum requirement. Relevant certification certificates shall
be submitted at tender stage.
Audit: (Valid Certification Certificates)
4.0 Documentation
The transformer manufacturing plant shall have all the systems and processes
documented for effective planning, operation and control. Every step involved in the
process of manufacturing transformers for REA shall be document and this
documentation shall be kept for the specified period as required by the standard and
should be presented to REA when called upon. These shall include but not limited to;
HSEQ Policies and Manuals, Process Manual, System Procedures, Quality Plans,
Manufacturing Procedures, Inspection Instructions, Test Methods, Process Checklists and
Forms.
A document control system shall be maintained, detailing procedures for changes,
authorization, revisions, approvals, indexing and achieve amongst other.
Audit: (Availability of above documents & a Document Control System)
8.3 Production
The production process shall be carried out under controlled conditions, the information
that describes the characteristics of the product shall be provided to the responsible staff
in form of detailed drawings, charts, instructions, etc. These shall be made available at
point of use.
A production quality plan shall be established and this shall highlight process specific
quality checks, equipment required, resources requirement, suitable monitoring and
measuring devices.
At every stage in the transformer manufacturing, quality & technical compliance checks
shall be performed by a qualified engineer before part is progressed to the next stage in
the production line
There shall be adequate equipment required for each production activity and these shall
be properly maintained
Traceability shall be established and maintained in the production process right from
materials acquisition, part assembly and product testing. Information regarding; material
supplier, staff name responsible for each activity, approvals at each stage, test done and
testing personnel among other shall be recorded using a transformer assembly form/card.
In the production process, items shall be identified by either labels, rating plates, stickers,
hang-on cards, hard stamping or marking with ink to indicate rating, drawing number,
etc. wherever standards are available for identification purposes such standards shall be
followed.
8.4 Testing
Test protocols according to IEC standards shall be established and the required
equipment put in place in a testing laboratory. All transformers shall be inspected and
tested as per IEC standards & REA specifications
New design shall be type tested by an internationally recognized testing laboratory and
type test reports shall be submitted to the client
Audit: (Availability of test protocols, Type test and routine test reports, Calibration
Reports)
8.5 Product Handling & Packing
All products shall be handled properly to prevent damage or deterioration throughout the
production process. Special handling tool should be in place for example cranes and
forklifts, and these should be inspected regularly.
Secure storage areas shall be provided to prevent transformers from getting damaged or
deteriorated before dispatch and all finished transformers shall be suitably marked for
clear identification.
Inspection, packing and delivery of finished transformers shall be done according to
REA’s specification
Audit: (Availability of proper handling tools, secure storage space, Procedure for
handling, Packaging, Storage & Dispatch)
PART 2: MATERIAL MANUAL
The minimum physical, mechanical and magnetic properties shall be as listed in table
below.
Items conforming to other national or international standards, which give equal or higher,
but not less quality requirements can be accepted.
Enameled round copper winding wire shall be of class 180, with a sole coating based on
polyesterimide resin. The film coating shall be essentially smooth and continuous, free
from streaks, blister and foreign material when examined with normal vision as wound on
the original spool. The copper for electrical purposes E-Cu 57 according to DIN 40500
teil 4 with minimum copper content of 99.90% shall be used.
The overall diameter, electrical characteristics and insulating properties of the enamel
covering shall be in accordance with the standards specified. In addition, copper wire
shall withstand electrical break through voltage of at least 450V in a salt solution (Water
+ 5% NaCl, weight to weight).
The maximum resistance value shall not be greater than the calculated with resistivity of
1/58 Ωmm2/m. the value shall be calculated for the minimum tolerated cross-sectional
area of the conductor. The maximum current density shall not exceed 2.5 – 3.0 A/mm2.
The nominal diameter of copper, its tolerances and the minimum values for elongation at
fracture shall be as indicated in table below.
Nominal diameter and minimum elongation at fracture of enameled for primary
winding
Nominal Minimum Conductor Minimum Maximum
diamete elongation (% of tolerance (-,+) increase due to overall diameter
r (mm) nominal diameter) µm the insulation (mm)
(µm)
Grade Grade 2 Grade Grade 2
1 1
0.250 22 4 17 32 0.281 0.297
0.280 22 4 18 33 0.312 0.329
0.315 23 4 19 35 0.349 0.367
0.355 23 4 20 38 0.392 0.411
0.400 24 5 21 40 0.439 0.459
0.450 25 5 22 42 0.491 0.513
0.500 25 5 24 45 0.544 0.566
0.560 26 6 25 47 0.606 0.630
0.630 27 6 27 50 0.679 0.704
0.710 28 7 28 53 0.762 0.789
0.800 28 8 30 56 0.855 0.884
0.900 29 9 32 60 0.959 0.989
1.000 30 10 34 63 1.062 1.094
1.120 30 11 34 65 1.184 1.217
1.250 31 13 35 67 1.316 1.349
1.400 32 14 36 69 1.468 1.502
1.600 32 16 38 71 1.670 1.706
1.800 32 18 39 73 1.872 1.909
2.000 33 20 40 75 2.074 2.112
2.240 33 22 41 77 2.316 2.355
2.500 33 25 42 79 2.578 2.618
2.800 34 28 43 81 2.880 2.922
3.150 34 32 45 84 3.233 3.276
3.550 35 36 46 86 3.635 3.679
4.000 35 40 47 89 4.088 4.133
4.500 36 45 49 92 4.591 4.637
5.000 36 50 50 94 5.093 5.141
For nominal conductor diameter above 1.600mm, the wire shall not exceed the maximum
spring back of 5 degrees.
Breakdown Voltage of enameled copper wire
Nominal Minimum breakdown voltage (r.m.s value) V
diameter (mm)
Grade 1 Grade 2
Room Elevated Room Elevated temperature
temperature temperature temperature
0.250 2100 1600 3900 2900
0.280 2200 1700 4000 3000
0.315 2200 1700 4100 3100
0.355 2300 1700 4300 3200
0.400 2300 1700 4400 3300
0.450 2300 1700 4400 3300
0.500 2400 1800 4600 3500
0.560 2500 1900 4600 3500
0.630 2600 2000 4800 3600
0.710 2600 2000 4800 3600
0.800 2600 2000 4900 3700
0.900 2700 2000 5000 3800
1.000 up to and 2700 2000 5000 3800
including 2.500
0ver 2.500 1300 1000 2500 1900
Items conforming to any other international or national standards, which are equal to or
higher but not less rigid, the standards and specifications stipulated may be offered.
The foil or strip shall be free of short, sharp deformations and edge wrappings. The foil or
strip shall also be free of holes, bubbles, dragon’s teeth, bumps, edge cracks, notches and
other deformations, which may be defined as manufacturing defects. The foil or strip
surface shall be shiny and free of grease and other impurities. Grease test according to
DIN 53364: Testing of plastic films, which can also be applied for copper foils or strips
can be conducted if required. The edges shall be without any blurr.
Aluminum for electrical purposes E-Al F7 according to DIN 40501 teil 4 with a
minimum aluminum content of 99.5% shall be used.
Physical and mechanical properties
Property Unit Type
Any other national or international standard that offers higher but not less quality
requirements can be used with prior approval from REA.
The transformer oil shall have the minimum characteristics of given in table below
Minimum characteristics of transformer oil
Test Test Method Value
Relative density ISO 3675:1998 0.871
Viscosity 40 deg. C.Cs ISO 3014:1993 12.0 (max)
Viscosity 20 deg. C.Cs ISO 3014:1993 31.0
Viscosity 0 deg. C.Cs ISO 3014:1993
Viscosity -15 deg. C.Cs ISO 3014:1993 350
Viscosity -30 deg. C.Cs ISO 3014:1993 1800 (max)
Flash point deg. C ISO 2719: 2002 154
Pour point deg. C ISO 3016: 1994 -40
Neutralization value mg.KOH/g IEC 60296: 2003 < 0.03
Corrosive sulphur BS 2000-315:1998 Non corrosive
Water content mg/kg IEC 60814: 1997 1.5
Breakdown Voltage kV IEC 60156: 1995 70
Resistively Ωm 20 deg. C IEC 60247: 2004 20
Dielectric dissipation factor 90 IEC 60247: 2004 0.001
deg. C
Gassing tendency mm/min IEC 60628: 1985 -1
Antioxidant additive IEC 60666: 1979 None
Oxidation Test:
Acidity mg.KOH/g IEC 61125: 1992 0.4
Sludge value % IEC 61125: 1992 0.1
PCB IEC 61619: 1997 None
The diamond dotted paper shall be diamond patterned epoxy papers and have shall the
following minimum properties;
Paper shall contain both sulphate wood pulp and cotton in a 50/50 mixture to
impart a combination of both favorable stiff and tensile properties.
The resin shall be on both sides of the paper and shall result in partial adhesion of
the electrical conductors to the layer insulation at a temperature between 100 0C –
130 0C.
Approximately 36% of the total area on each side should be printed with epoxy
resin of 9.5×9.5mm2
The thickness of the partial coating of resin shall be 0.01mm on each side.
The epoxy resin must not affect the properties of mineral oil used in the
transformer.
Single layer diamond dotted paper shall generally have a nominal thickness of
0.13mm and 0.25mm.
When the insulation is specified as double layer diamond dotted paper (DDP), it
shall have two layers of DDP glued under dry conditions. Double layer DDP shall
generally have a nominal thickness of 0.15mm, comprising of two 0.075mm thick
insulation paper.
The tap selector shall be suitable for off load operation and immersing in transformer oil
and to be used in hermetically sealed transformers. These shall be operated generally at
nominal voltages of 36kV and 12kV with different current ratings. The number of tap
positions shall be as per REA specifications.
The materials to be used in different parts of the tap selector are shown in table below
Materials for different parts of tap selector
Part Material
Steel Parts Stainless steel
Polyamide Parts Nylon 66, Strong against UV light
Aluminum Parts GAlSi12Cu, Protected from anodic
oxidation
Brass Parts CuZn40Pb2 Ms60F34
Copper Parts E-Cu F25
Insulator Parts Paper phenol plastic resin based laminates
Any changes to material shall be given prior approval.
6.0 Pressure Relief Valve
Pressure relief valve shall be manufactured in accordance with IEEE Std C57.12.22-1993
or any other national and international standard that offers equal or higher but not less
quality requirements.
The pressure valve shall operate at 0.35 bars and shall reseal at the same pressure.
Items supplied shall be in accordance with the standards specified below or later editions
and or amendments thereof
BS EN 10029: 1991
BS 7668: 2004
BS EN 10025-1:2004
BS EN 10025-3:2004
BS EN 10025-4:2004
BS EN 10210-1:2006
Items conforming to any other international or national standards, which are equal to or
higher but not less, rigid than the standards and specifications stipulated may be offered.
The mild steel components shall be free from corrosion, oil/grease and burrs. The
minimum thickness of the mild steel for up to 400kVA transformer shall be between
4mm to 6mm and for 500 – 600kVA shall be 6mm to 10mm.
8.0 Radiator
The radiator shall be used convectional cooling of the transformer so that designed
temperature rise in the inside transformer is with desired limits. The items used shall be
formed out of steel in compliance with standards specified below or later editions and or
amendments thereof;
DIN EN 10131: 1992
DIN 1623: 2009
The (items formed out of) steel conforming to any other international or national
standards which are equal to or higher but not less rigid than the standards and
specification stipulated may be offered.
All radiator surfaces should be free from oil and the minimum thickness shall be 0.2mm.
PART 3: TESTING PROTOCOLS
1.0 Introduction
The Client in accordance with the relevant IEC and ISO standards shall inspect the
manufacturing plant, its process and products. The tests on the products shall include:
Work instructions
Always make sure that the instrument body is earthed before the meter is
switched ON.
Do not try to open the instrument while testing oil.
Always follow general safety instructions of the area
Purpose
To assess the Full Load Loss (copper loss) and the impedance voltage of a transformer.
Tests should be performed as per IEC – 60076 test standards.
Apparatus
AC Analyser
Manual for the AC analyser.
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth
Make sure the oil level of the transformer is at the top level.
Make sure that the transformer tap selector is at the rated tap position.
Procedure
Short circuit the low voltage winding bushing terminals using a thick flat copper
bar which is sufficient to carry rated low voltage current.
Connect A.B.C bushing leads to the respective test leads.
Calculate the rated current of the high voltage winding and select the CT tap
position according to it.
Apply the CT & PT ratio values to the meter.
Switch on the air circuit breaker.
Measure the parameters after injecting the desired rated current by pressing the
start/stop button of the instrument. Pressing the start/stop button again, the
measured values can be stored on the display of the meter.
Switch off the air circuit breaker.
Care should be taken to avoid supplying current for longer durations during the
test in order to prevent heating of the windings, which eventually introduce
additional losses.
Record the room temperature
Acceptance criteria
Deviation of full load losses corrected to 750 C shall be within 15% of the
specified value.
Total losses – deviation of the component losses should be within 15% while
maintaining the deviation of the total losses within10% of the specified value.
Work instructions for safety
Make sure that the meter body is switched to earth before switch ON the meter.
Always short circuit the secondary terminals of the current transformers before
switch off the voltage to the transformer.
Always follow general safety instruction of the area.
3.10 Zero Sequence Impedance Test
Purpose
To determine the zero sequence impedance of the transformer. Test should be done as per
IEC – 76 test standards.
Apparatus
AC Analyzer
Votmeter
Preparation of sample
Transformer should be isolated
Clean the bushings thoroughly with a clean piece of cloth.
Make sure that the oil level of the transformer is at the top level.
Make sure that the transformer tap selector is at rated tap position.
Procedure
Short-circuit High Voltage bushing terminals of the three phases.
Connect the circuit as shown in the circuit arrangement.
Apply a single phase voltage of about 200V with the same frequency as the
operating frequency of the transformer across the neutral and the short circuited
point.
Measure the voltage (V) and current (I).
Calculate the zero sequence impedance (Z0) using the formula Z0 = 3V/I
Acceptance Criteria.
The zero sequence impedance should be within a 10% deviation from the
designed value.
Work instructions for safety
After completion of the circuit wiring, apply a lower voltage and gradually
increase the voltage up to the required value.
Switch off the circuit before disconnection.
Always follow general safety instruction of the area
Acceptance Criteria
Top oil temperature rise should be less than 550 C
Winding temperature rise should be less that 600 C
Work instructions for safety
Make sure the meter body is connected to the earth, before switching ON the
meter.
Always short the secondary terminals of the current transformers before switching
off the voltage to the transformer.
Use hand gloves to remove the leads from heated terminals of the transformer.
Always follow general safety instruction of the area.
3.13 Measurement Of Electrical Break Through Voltage Of Copper Wire
Purpose
This test is carried out to assess the insulation of copper wire.
Apparatus
Voltage regulator (Variable between 0 – 440V)
Salt solution (Water +5% NaCl, weight to weight)
Plastic rod (for forming the copper thread according to the table below)
Safety
All safety procedures outlined in test method for dielectric voltage withstand test shall be
followed during this test
Procedure
Get a copper sampling with a length of at least 6m.
Wind the copper sample or the rod in spiral.
Prepare salt solution (water + salt in 1:5% weight ratio). Note: 1 g of water = 1ml
of water.
Place the prepared copper spiral in the salt solution with terminals at least 20mm
over the surface of the liquid.
Touch one set probe of voltage regulator to the salt solution and one end of
copper wire should be isolated and kept 20mm over the liquid level.
Start with 0V and then increase the voltage up to 440V and maintain it for 30secs
and check the break through voltage.
Acceptance Criteria
There should not be any flash over point throughout the selected length
Diameter of thread Diameter of rod
0.100mm – 0.315mm 3.0mm
0.315mm – 1.000mm 18.0mm
1.000mm – 2.240mm 18.0mm
Work Instructions for safety
Connect the copper wire to the terminals and immerse in salt water prior to switch
ON.
Do not touch the test leads, sample or salt solution while switch ON.
Always follow general safety instruction of the area.
3.14 Dry Power Frequency Voltage Withstand Test
Purpose
To identify any flashover or punch of the bushings
Apparatus
High voltage test set
Procedure
Clamp the bushing as its intended use and apply the power frequency voltage as in given
table
Acceptance Criteria
The bushing should be considered to have passed the test if no flashover or puncture
occurs. If there is a puncture, the bushing shall be considered to have failed the test. If a
flashover occurs the test shall be repeated once only. If during the repetition of the test no
flashover or puncture occurs the bushing shall be considered to have passed the test.
Nominal Voltage kV (rms) Dry lightning impulse Power frequency withstand
withstand voltage voltage dry & wet kV (rms)
1.2/50micro sec kV (peak)
3.6 40 10
7.2 60 20
12 75 28
17.5 95 38
24 125 50
36 170 70
Work instructions for safety
Never switch ON the HV tester when someone is inside the testing area.
Switch OFF the output voltage before change the HV connections.
Do not operate other electrical instruments while HV tester is switched ON.
Always follow general safety instruction of the area.
It is important that inspection be made upon arrival of the transformer for any signs of
damage incurred during shipment. This inspection should be made after removal of the
transformer from the truck. The following items should be inspected closely for damage:
High voltage and low voltage bushings should be checked for cracks, chips, and
leaks.
All external accessories should be checked for breakage, loss, and leaks.
Tank and radiators should be inspected for leaks, dents, scratches, and other signs
of rough handling.
Paint should be inspected for damage.
Oil level gauge should be noted, along with the ambient temperature measurement
The factory shall be notified of any defects noted. External damage, or evidence of rough
handling, may be an indication of internal damage.
If any parts of the transformer have been removed for shipping, these will be noted on the
Bill of Lading as separate items. These items should be checked for shipping damage as
well.
Post shipping testing:
All transformers shall be subjected to routine tests according to IEC – 60076, by REA
after delivery at REA Test Laboratory or any other approved testing facility
recommended by REA. Test certificates shall be issued before delivery to site.
Transformers that fail at this stage shall be rejected and the supplier shall replace them at
his cost.
APPENDICES