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    | oen000000000000000900000009999099909930 0 CONTENTS ACKNOWLEDGEMENT INTRODUCTION PRINCIPLE OF TRANSFORMER CONSTRUCTION OF TRANSFORMER TYPES OF TRANSFORMER MATERIAL USED IN TRANSFORMER COOLING'ARRANGEM ENTS TRANSFORMER AUXILIARIES SPECIFICATION OF TRANSFORMER REPAIRING OF TRANSFORMER - d TESTING OF TRANSFORMER : ACKNOWLEDGEMENT I take this opportunity to express my deep sense of gratitude towards all those individuals who provided a helping hand to me in making this Training Semester Report. at I’m greatly thankful to Senior Engineer Mr. Pardeep Sharma who provided. me, an opportunity to get training under ‘him, in the Amosons Transformer (: ‘Mohall). 'm highly grateful to him for his valuable, quidance, constant encouragement, constructive cniticism and sincere 06-operation. {'m indebted to him for.his unconditional help that he offered me, throughout the It' was a great experience. to > get training under_him in a a Ee > a ’ a > . > a > a > e > oO > oO 3 e a he 2 oO e > oe. +. a > eo. -_ 2 2 5 3 3 disciplined. environment. | herby’also thank the co-operative. staff jnembers..and workers of “T.R.W.Allfor.their wholehearted support. a Lastly i'would like to take this opportunity: in expressing my deep sense of respéct to my parents to whom I’m indebted for their blessings and love. © 0; OOO 9,9, 89404 Oy y 994 Oy 94 9y9, = @B@eoeoooeoovoooOOOGRGRGRRR0R2Raaggea2a0 DF INTRODUCTION The transformer is a device, or a machine, that transfers electrical energy from one electrical circuit to another electrical circuit through the medium of magnetic field and without a change in the frequency. The electric circuit which receives the energy from the main supply is called PRIMARY WINDING and which delivers the electrical energy to the load is called the SECONDARY WINGING. Actually, the transformer is. an electromagnetic energy conversion device, since the energy received by the primary winding is first converted to magnetic energy and it is then reconverted to the useful electrical energy. in the other circuits (secondary winding circuit, third winding circuit etc.). The two windings are not electrically coupled but only magnetically. This magnetic coupling allows the transfer of energy in both directions, from high-voltage to low-voltage and vice- versa. If the transfer of energy occurs at the same voltage, the purpose of the transformer is merely. to isolate the two-electrie circuits and this use is very rare in power applications. If the secondary winding has more turns than the primary winding, then the secondary.voltage is higher than the primary voltage and the transformer is called a set-up transformer. In case the secondary winding has less turns than the primary winding, then the secondary voltage is less than the primary voltage and the transformer is cafled step-down transformer. Note that a step-up transformer can be used as q step-down transformer, in which case the secondary of step- up transformer becomes the primary of: step-down transformer. Actually a transformer can be teimed a step-up or step-down transformer only after it has ‘been put fhto service. Therefore, when referring to. the windings of a particular transformer, the terms high-voltage winding and low-Voltage winding Should be used instead of primary and secondary winding pee The transformer is a static piece of élecitié machinery and concepts about its behavior can be understood in a comparatively simple manner. Insulation consideration limit the generation of alternator (ac generator or synchronous generator) voltages from about 11 to 22 kV, By: means.of transformers, this voltage is stepped up to higher economical transmission voltage, 400 kV or even higher, in order to reduce the transmission losses: Wherever the electrical energy is required, transformers are installed to step down the voltage suitable for its utilization for motors, illumination purposes etc. Thus the transformer is the main reason for the widespread popularity of ac. systems over d.c. systems. E ® oO eo e oe ° o oe ° oe o e e eo e °e tC) oO e eo e e e a e o eo @ e @ e @ e e@ o , PRINCIPLE OF A TRANSFORMER ‘A Transformer is a static (or. stationary) piece of apparatus by means of which electric power in.one circuit is transformed into electric power of the same frequency in another circuit: The physical basis of a transformer is mutual induction between two circuits linked by a common magnetic flux. In its simplest form, it consists of two inductive coils which are electrically separated but magnetically linked through a patch of low reluctance. The two coils possess’high mutual inductance. Iffone coil is connééted to a source of alternating voltage, an afternating flux is set up inthe laminated:core, most of which is linked with the other coil in which. it produces tiutually induced ¢.m.f. (actording to faraday’s Laws of Electrormagitétic induction’e = M"/,) 1 The second’coil circlit is closed, a current flows in it and 0 electric energy is transferred ( entirely magnetically)-trom the first coil to the second coil, ‘The first coil, in which electric energy is fed from the a.c. supply mains, is called primary winding and other from which energy is drawn out, is called secondary winding. pene0000000000-9.09:90090009909999990990 9 BD MAGI AN EQUIVALE ST TAG OF ACTUAL TRANS FORIIER \ ruction of a Transformer from each other. the core is actually a magn type of construction used, the transformers are cla as : (i) core type, and (ii) shell type. , Core type Transformers: the legs or limbs of the core. a limbs and have a cross-seetional ar limbs. reactance low. Weeoee0ve000000999003999000900999999009090 The Transformer is basically a very simple device. it consis windings wound on a laminated magnetic core and insulated from iron and circuit which serves as a Batch for the mutual Mux. Therefore, the windings encircle the "eee and the core encircles the windings. There are two general types “of constructions employed to achieve this in transformers. Consequently, depending upon the ified into two categories i i The magnetic core is built of laminations to-form-a-réetangular frgme and the windings are ‘arrahged-concenirically” with cacti ‘other around The top and-bottom members, called the yokes, conriéet the two sequal to: or_grédter thaiv-that. of the A single phase transformer may be designed with prim: winding wound on one limb and secondary winding on the other limb. This arrangement results in a large separation between the primary.the secondary windings and hence a large leakage reactance. In actual practice, each limb carries on half of the primary winding andone half of the secondary winding so that the two windings can be closely-coupled togetirer to keep the leakage \ BaKEUITE FORMER SHELL TYPE GORE ere: HY, WINDING: j J ©0000 8 Bow v'wes 000086 00000000090099999399909099 g is wound on the inside nearerto the The low voltage (L.v.) windiny core while the high voltage (h.v.) wisiding is wound over the Ly. winding away from core in order to reduce the amount ‘of. msulaling “materials required. Shell type Transformers: =) In shell type Transformers the windirigs ate put around the central timb and the flux path is completed through two side Timbs, The central limb carries total mutual flux.. Consequently, the cross-sectional area (and hence width) of the central limbs is twice that of each of the side limbs. je Both high voltage (hwy,) and: low. voltage (I.v.). windings are i fv neailg are. shaped: like © ately. ‘This, divided into a number of coils. pancakes and are arranged. longitudinally. along, the core alter gives rise to a sandwich: winding, with h.v. coils, sand-wiched between Iv. coils. In the core type the-impression is ‘cre ‘windings ated that ‘thi surround the core, whereas with the shell type that the cores surround the windings. Woweeooono0n00o00d0000900999999999908900 F) BL SHINGS CONNECTED TO HV TERMINAL, Wd © © © © 0.8 0. 0-9.0:9:0_9_9.9.9 9.0.6.9. 9.9.9.9.9.9.939.9.8 0630 408 In general, important tasks performed by the transformers are For decreasing or increasing voltage and current levels from one circuit to another circuit transformer consist of following parts-> 1). Transformer Box:- This encloses the main core and contained with TRANSFORMER OIL. Further this box consist of — (i) TRANSFORMER COVER: This covers the open box and makes the transformer AIR TIGHT. This also form the base for resting of OIL TANK. This cover is tied to the rest box with nut bolts. The COVER are has a OUTLET PIPE. This OUTLET PIPE is Provided so that the gases formed during heating of oil and burning of oil due to over heating of coils may get an escape. The cover is also provided with a SAFETY VALVE. This Valve operates when the pressure of the Transformer Oil inside the tank rises up to the safety limits.” (ii) OIL TANK: This OIL FANK is a reservoir for transformer oil. It is mounted on the transformer oot This tank is made of cast iron. (ii). AR BREATHER. : AIR BI THER is a cylinder made of Aluminum because Aluminum forms a protective layer of Aluminum oxide. This layer does not react with the Silica Gel\ contained in the Breather. The. air, is, required. for creating air, Pressufe on the transformer. oil for its movement -ffom. oil:tank-to-the: transformer box. Air should not enter to the transformer box because’ it can react with the oil and can reduce tise formation Of.electromagnet. (iv). TERMINAL BUSHES, There are seven bushes attached to the transformer box. Three of them are HIGH TENSION BUSHES and remaining four are LOW TENSION BUSHES. These bushes consist of good quality insulation material insulators, HIGH TENSION BUSHES are larger in size than. the LOW TENSION BUSHES. The material used for manufacturing these bushes is mostly the PORCALIN (CHINA CLAY). The H.T. Bushes may be attached to the Transformer Tank or they may be attaching to the Transformer Cover. This is dependent on the Type of Make or Manufacturer of the Transformer. The H.T. Bushes are to the Transformer cover or tank with the help of Bush Clamp. This Bush Clamp is made of mild steel or cast iron. It should be noted that the Dimensions of the H.T. & L.T. Bushes is not according to the Manufacturer of the Transformer and not depends on the Rating of the Transformer. Their Dimensions are Standard size. The Bushes of all the Distribution Transformers are similar in size and shape. The difference between them is their Dielectric Strength (v). RADIATORS. These are that part of transformer which is designed in such a way that will increase the surface area. This large surface area is required for cooling purposes. Their design varies with make of transformer and rating of the transformer. TAP CHANGERS ON TRANSFORMERS The modern equipments, utilizing electrical energy, are designed to operate satisfactorily at one voltage level. It is for paramount importance to keep the consumers terminal voltage within the prescribed. limits. The transformer output voltage and hence the consumer terminal voltage can be controlled by providing taps either on the primary or on the secondary side. The principle of regulating the secondary output voltage is based on changing the number of turns in the primary or secondary. Let V1, N1 and V2, N2 be the primary and secondary quantities. If N1 is decreased, emf per turn on primary =V1/N1 increases, therefore secondary output voltage (V1/N1)N2 increases. On the other hgnd, if N2 is increased keeping N1 constant, the secondary output voltage CIN Na also increases. In other words, decreasing primary tums N1 has the same effect as that of increasing the secondary tums N2. The taps which help in altering the turns ratio, may’ be placed on thé * primary or secondary side. The choice bets nthe: two sides should: be based on maintaining the voltage per turn gonstant as far as- possible: If primary voltage per turn decreases, the core flux decreases aid this resultsin ~ poor utilization of the core, though core losses.are reduced.on the other hand, if primary voltage per turn increasés, the core flux increasesb and this results in magnetic saturation of the core, more-core losses , increased magnetizing current and pronounced third harmonic. In transformers at the generating stations, the primary voltage can be Kept almost constant; consequently. the taps should be provided on the secondary side. If transformer is energized from a variable voltage source, as at the receiving end of transmission line, the taps should be provided on the primary side. Other factors for considering the side of taps. 1. Transformers with large turns ratio, are tapped on the h.v. side , since this, enables a smoother control of the output voltage, in large steps, which is usually undesirable. 2. Tap changing gear on the h.v. side will have to handle low currents, through more insulation will have to be provided. OQ % HB VYQVW™AW™UVW™W”'YVNRV*}'™’’UW’W!|ZGO.9-0-9-999999909099000) eo0e0e2eo00000000090000900999909 992 9.9,0.9.9,9,9,9 | 3. Itis difficult to tap the Lv. winding since it is placed to next to the core due We ansulation considerations. The h.v. winding placed outside the Lv. winding is easily accessible and can therefore, be tapped without any difficulty. Aiso the transformer winding should be tapped at the end or in the iniddle, the currents in the primary and secondary coils must flan in opposite directions. These currents interact with leakage flux in between the two coils Suppose the winding is tapped at one end. When some of the turns are cut out by tap changer, axial forces, in addition to radial forces are also developed. Under short circuit conditions, the axial fc the coils axially, are very large. In order to obviate this, the physical position of the tapped coils should be in the middle of winding, so- lightening surges? ; TAP CHANGERS ON TRANSFORMERS The modern equipments, utilizing electrical energy, aré ‘designed to Operate satisfactorily at one voltage level. It is! impor Keep the consumers terminal. voltage: within:- transformer output voltage and hence the consti Controlled by providing taps either on the primary The principle of regulating the secondary output voltagé'is based on changing the number of turns in the primary or secondary. Let V4, N4 and v2, N2 be the primary and secondary quantities. If Ni ie decreased, emf per turn” eeimary =V4IN1 increases, therefore secondary output voltage (V1/N1)N2 increases. On the other hand, if N2 is increased keeping N1 constant, the Secondary output voltage (V1/N1)N2 also increages, In other: words, decreasing primary turns N1 has the same effect ae that of increasing the secondary turns N2. Ou Ou Ov OyOyOuOuOu Oy 94 By 949 ey ®YIG®VPyAV9 V9 49 VP 9WP GPG GPy PIAA PL DLT primary voltage per turn decreases, the core flux decreases and this results in poor utilization of the core, though core losses are reduced.on the other hand, if primary voltage per turn increases, the core flux increasesb and this results in magnetic saturation of the core, more core losses , increased magnetizing current and pronounced third harmonic. In transformers at the generating stations, the primary voltage can be kept almost constant, consequently the taps should be provided on the secondary side. If transformer is energized from a variable voltage source, as at the receiving end of transmission line, the taps should be provided on the primary side. Other factors for considering the side of taps. 1. Transformers with large turns ratio, are tapped on the h.v. side , since this enables a smoother control of the oufput voltage, in large steps, which is usually undesirable. 2. Tap changing gear on the h.v. side will have to handle low currents, through more insulation will have to be provided. 3. It is difficult to tap the I.v. winding since it is placed to next to the core due to insulation considerations. The h.v. winding placed outside the Lv. winding is easily accessible and can therefore, be tapped without any difficulty. ; Also the transformer winding should be tapped at the end or in the middle, the curfents in the primary and secondary coils must flow in opposite directions. These currents interact with leakage flux in between the two coils and produce g radiaf force, repelling eachother. This radial force tends to cornpress the’inner coil on to the core and burst the outer coil away from the core. The repelling force may be regarded as acting along the fine joining the centers of gravity ofthe primary and secondary coils. 3 Stick wae ee Suppose the winding is tapped at one end: When:some-of the tumns:are cut out by tap changer, axial forces, in- addition to radial forces are also developed. Under short circuit conditions, the axial forces tending to compress the coils axially, are very large. In order to obviate this, the physical position of the tapped coils should be in the middle of winding, so that no axial forces arise after some turns are cut out. Electrically the tap changer is connected Where the voltage to neutral is minimum. For example, in'star connéctéd to form the star point, though physically the tapped coils are are placed in the middle of the winding. This however is not possible in’ delta connected transformers, where it is electrically essential to provide the tapped coils, in the middle so that the tap changing gear is far removed from the line and lightening surges. ® @ © © 0-0-0-0-0-9-0-9- 9-9-9-9.909-9.9.9 9-9 -9.9.9.0.9.9.9.9.9.0. 9.9.0.0] (VI) OFF LOAD (NO-LOAD) TAP CHANGER This tap changer is used for seasonal voltage variations. For eg. Let the tap changer has six studs marked from 1 to 6 . The winding is tapped at six studs. The tapping leads are connected to six correspondingly marked stationary studs. The tapping leads arranged in circle. The face plate carrying the six studs, can be mounted anywhere on the transformer, say on yoke or any other convenient place. The rotatable arm can be rotated by means of handwheel, from outside the tank 'f the winding is at tapped at 2.5% interval, then with the'rotatable arm, 1. At studs 1,2; full winding is in circuit 2. At studs 2,3; 97.5% of the winding is in ckt. 3. At studs 3,4; 95% of the winding is in circuit 4. At studs 4,5; 92.5% of the winding is in circuit 5. At studs 5,6; 90% of the winding is in circuit. A stop switch fixes the final position and prevents the arm R from being rotated clockwise. In the absence of stop switch, the arm may come in contact with studs 4 to 6. In such a case, only the lower part of the winding is cut out of the circuit and this is undesirable from mechanical stress considerations. The tap ‘changing must be carried out only after the transformer is disconnected from the: supply. Suppose the arm is at studs 2and 3, the transformer is ftst de-energised and then the arm is rotated to bridge studs 2 and 3. after this transformer is switched on to the ‘supply and now 97.5% of the winding remains in the circuit. 2). TRANSFCRMER CORE: wel st an rte The core is the most important part of the transformer. The coils are “fitted on the core limbs. The core form. the ‘electromagnet.when INPUT. VOLTAG is provided to the HIGH TENSION’ BUSHES. and INDUCED CURRENT follows through it. + ‘The core of transformer consists of : a) Three LIMBS: They are the perpendicular part of the core the limbs consist of SOFT IRON STAMPINGS. The main functions of the limbs are:- > hold the coils, > form the electromagnet by induction and completing the path of mmf. 2 U u ha au a 00890909990908090090090 09 a “ *¢ @0000 @uuuu oe gu MUBTYUVVUVUVe b) Two YOKES: SOFT IRON STAMPINGS. The thickness of individual stamping is 0.5mm. The core is divided in these stampings so that the hystrisis losses (CORE LOSSES) may be reduced the core may get converted into good electromagnet during working of transformer. c) Two CORE CHANNELS: These channels serve the purpose of holding the stampings of the yoke tightly. The channel is made up of cast iron alloy mainly steel. These are two in number, upper channel set and lower channel set. - d). BARRIERS: 5 = ia The BARRIER is a PRESS BOARD wall double folded on the side of iron Tods. The main purpose of the BARIER is to isolate the coils of the limbs from each other. The thickness of the Press Board used for the Barrier is 1.5mm. CAUSES OF GETTING DAMAGE OF TRANSFORMER 1. Damage due to over voltage. 2. Damage due to over current. 3, Damage due to over load. 4. Short circuiting of transmission lines. Damages to the transformer Reparable defects. Burning of coils. Short circuiting of coils. | Damage of bushes. Irreparable defects. Damage of box of transformer due flash. - Damage of the stamping due to high temperature. VY vvve @0e0000009999900999 998900909 9 9 0-9-9-0-9-9-0:90.9. | The damaged transformer are brought to the store from various places, almost from whole of Punjab even there are so many transformer repair workshop. The transformers are not taken with respect to their kVA rating or kV rating but in terms of Units. The different units are > 25kVA---1 unit 63kVA —1.5 units 100kKVA---2 units 200kVA---4 units Before 1995, this was the rule that only the damaged: part of the transformer was replaced and the other parts were used as ‘such, But know all internal parts such as >Insulation Material >Transformer Oil. >Coil Sets (H.T. & L.T.). - are replaced and a new transformer set is provided to the store. Only the box or tank of the transformer is not changed if the tank is not seriously damaged. 9899929283200 0 00082282 09999999099900090 07% vu KEY DIAGRAMOF STEPS IN REPAIRING OF TRANSFORMER G @00008 Gu So 00 GuUuG e ae Ga haa rie Fipnnaiignes ? 2 oy DIFFERENT SECTIONS OF TRANSFORMER REPAIR WORKSHOP NO. 1. Washing Section 2. Core Repair Section 3. Coil Fabrication 4. Core Ovening Section. 5. Box-up Section. 6. Oil filling Section. 7. Box up Section, 8. Pre-testing section 9. Welding Section, 10. Painting Section. 11. Final testing, Different equipments in Transformer Repair Workshop 1. Lifting Equipments include- a. crane, This mechanical equipment is manually operated. This crane has movements- horizontal, vertical, and downwards. This crane is used to lift the heavy transformer cores and tanks to perform different repairs b, Hydraulically operated Core and Tank carrier. 2. Hard Board Cutting and Paper Cutting Machine. 3, Ovens and Heaters 4. Transformef Oil Dehydrating and Purification Set. 5: SOOKVA. Distribution Transformer set for workshop requiremenis. 6. Oil filling and Draining Set 7. Welding Sets. There are two types of welding sets in TRW. > D.C. welding set > A.C. welding set 8. Transformer Testing Equipments. i : 1. Coil Megger Testing Set s as . Transformer Turn Ratio Set. ie 5 . Transformer Oil Testing Set No Load and Full Load Testing Set High Pressure Testing Set. . Double Frequency and Double Voltage Testing Set( DVDF Testing Set). This workshop has capability of repairing the transformer of rating 25kVA to 200kVA. The repair of transformer is performed in the below drawn Step wise diagram. OAawon ® 6 Py 6 é 3 3 a a 3 3 6 é Bs 3 3 3 3 3 3a a A é 6 oe ° oe eo @ oe eo ° ° © ® DETAILS OF STEPS IN REPAIRING THE TRANSFORMER The Transformer Repair Workshop receive the damaged transformer core, Box ( tank ), cover, but not the auxiliary like the High Tension and Low Tension Bushes, protection devices, nuts and bolts, transformer oil, Air breather. These all auxiliary are removed by the transformer store workers The different parts are sent to the different sections of Transformer Repair Workshop Pre- installation formalities done to the Transformer “texnstallation formalities done to the Transformer Before the transformer is given to the transformer repair workshop, there are some formalities are done. These are as follows- ai 1. Writing of the core fitter name on the transformer core and on the transformer tank. - A serial number is given to each transformer .anid this number is also written on the transformer core and transformer tank. This Serial numberiAS@rication Section, b. Quantity of Transformer Oil. ©. number of H.T. and L.T. bushes d. type of insulation paper and insulation board: Materials required to repair the Transformer are listed :- [ S.No. | Description of | ° o ° o 25 kVA [63 kVA | 100 200 materials KVA | KVA e 1. | Fibre glass sleev of 3m «(| 3.5m 4m Sm x 4mm 2.__| Bakelite Tube 3/6” 2m 25m ___|3m 4m ° 3._ HT. cap ISI3347 3 3 3 3 ° 4. | LT. Brass caps 4, 4 4 4 1si3347 © 5._| Cotton cloth waste 0.75kg |0.75kg | 0.75kg - | 0:75kg ° 6._| Cotton yarn waste 0.75kg_[0.75kg: | 0.75kg’ | 0.75kq 7. | Silica gel Breather 1 1 rf aie e 240gm ° 8._| Silica gel 250gm | 250gm_|250gm | 250gm 9. | Aluminum Ferroles eo ° 4mm 6 = = = ° 6mm | 6 66 6 = ; 10mm | — = 6 9 e 7 témm = = "24 ° {70mm = = = ° 150mm | — 1 = = i 185mm_—|— = 2 = © 300mm : ° 10._| MS washers e 14. [Aluminum Thimbles & 7omm o 95mm = 120mm | — = 4 = 240mm | — = = 8 e “12. | Caustic Soda 0.5kg | 0.5kg —[0.5kg _ | 0.5kg o 13. (PVA. 25gm_|25gm | 25g. |25gm_ ° 14. | Grey Paint O.Sitr. [0.75itr- [O.75itr. | Ate. 15._| Transformer Oil Solr. | 436itr. | 203itr. | 265itr © 16._|White Cotton Tape troll [1%roll_|1%roll_|2 roll ° 17. | Insulating Press Board e imm [2.5kg | _3kg___|4kg 7kg @ 2mm | 1.5kg 1.75kg | 2.5kg | 3.25kg @ ) ® e e __T 3mm | tke [4.5kg | kg 2g i 4mm _| 1kg T5kg 2kg | 2kg 18. | Neo. Prereane bounded Washer Fig No.7 | 3 3 3 3 [_ 3 8 8 8 8 5 4 4 4 4 6/4 4 4 4 19._| Zinc Chromate OSI |O-5itr OSI | 0.75Itr 20. | Brass nuts 21 24 21 9 (12x1%25%12) a 21. [Brass rods 12mm 1.3kg [4.3kg /-3kg 16. Skg. | Témm 22. | Brass check 4 14 14 6 nuts(12x1.758) 23,_| HT. Bush 3347 3 3 a 5 24. | LT. Bush 3347 5 3 Bi 3 25. i 26. | Gasket sheet % 113 13 % 45mm(3'x2') 70 3 Si 3 *~ oO e ° e e ° o ° o o ° o eo o ° © o ° oe e ° o e oe oO @ © © e @ e e e e @ | trem teary, eo ° ° oO eo oe ° ° ° ° ° ° oO eo oO o 6 6 36 3 A 38 38 3 é oO ° o ° oo © ° ° ® ° e A. Washing Section. The WASHING SECTION consist of a WATER COMPRESSER and WATER PUMP. There are two operations performed in the washing section The two operations are as follows- 1. Washing with water. 2. coating with Zinc chromate. 1. Washing with water. The box of the transformer is send to the Washing Section. In the washing section , the box of the transformer is washed from inside. This washing is done to remove the following materials- 1. Carbon particles- these carbon particles are produced due to a) Burning of oil b) Burning of Insulating paper of coils and other used‘in-the transformer. 2. Oil particles stick to the transformer box and in the cooling tubes. 3. Other compounds produced from hot oi! and Iron box. For proper washing of the transformer tank, there is a pressure washer. This machine consists of pump and huge water tank. 2. Coating with Zinc chromate. z 7 After cea with water and drying the transformer tank is coated with a chemical compound called Zinc Chromate. This chemical coating is provided to- # check the chemical reaction of transformer oil and tnetel pert ie. tron: # to reduce the losses, fe Sets i The quantity of Zinc chromate to provide’ coating to the 25kVA, 63kVA, ~ 100KVA, 200KVA transformer is 0.5 liters, 0.5 liters; 0.5liters, 0.75liters. u -9.9-%%%%9,9,9,9 99 9: 6. @ © 0.0 © @ © © 9.0.0 0,9,.9,9.0.8.9 90060 B. Core Repair Section The core of the damaged transformer 's given to the Core Repair Section. The worker of the Cor © Repair Section is called CORE FITTER When the damaged transformer frame the CORE FITTER is written. on ane transformer tank. This identification i of the transformer after the complet. The repair of the Core of the Transformer consist of followi 1. Separation of core of the transformer from the box --> The core is: Separated from the tank by the use of a big crane. This crane whieh nally Operated ie muscular power 1s uses The crane has Lift Gears which make the heavy loads easy to lift by worker. 2 UNTYING OF CORE and REI YOKE>The core is made loose a OF the ng, of channel the PRESS BOARD is f Of the UPPERJYOKE are removed. Then thes any cleaning agent or simple transformer oll ing steps> 3.Removal of damaged coils from the iron'timbs> When the damaged core is Provided to the core fitter, core fitter remove the damaged coils, After removal of the Coils the three limbs of the iron core Ind driek are cleaned with the oil a ried. Then it is inspected that if the stampings of all the three limbs are in good condition. > If the stampings are Not in good condition the they are changed. Else these stampings are cleaned with oil, it should be noted that only the yoke stampings are removed. 4, Providing the requirements for the epair of the core->The core fitter is Provided with the requirements wh ich includes — a. Cotton tape roll b. H.T. and L.T. coil sets c. Insulation Paper qd. Insulation press board e PVA adhesive The quantity of these re rating of transformer is different, quirements are different for different kVA o 0 0 00 0 0066 0 0 0'0'0 0 00 0 6 4/088 06 6 88 6 e Name of company the coils of consider the following factors. A. Make of the transformer. This includes > size of the trnasformer. > diameter of the three limbs. b. KVA rating of transformer. The correct order is placed to the coil fabri ication section. The details of the Coll fabrication section are given later in the report. It should be noted that the Low TENSION COIL is fitted first and then Ground this coil the HIGH TENSION COIL set is Mt. E transformer from inside. These clearances are important aspe losses and hence improve th; ‘cts to reduce the transformer fe transformer efficiency, ] o ° The chart on the CORE FITTER works is as under-> © INTERNAL CLERANCES ' aa ] ° as per the IS-2026 (PART -1)/ 1997 in the | Be | TRANSFORMER TANK [A)_JJBETWEEN HV. winding and LV. winding 1omm |) ° I) BETWEEN H.V. winding and T/F TANK ° | (i) NON-BUSHING SIDES 25mm a (ii) BUSHING SIDES 40mm (ii) BETWEEN SECTIONS OF HV. losmm | © ) WINDINGS o (iv) BETWEEN H.V. WINDING 1omm Es (V)BETWEEN H.V. WINDING AND YOKE 25mm (at ends) WITH y ° a — Enos RINGS © [ ‘| (vi) BETWEEN L.V. WINDING AND YOKE 1Oomm o (vil) BETWEEN YOKE AND INSIDE OF TANK |l100mm Be TOP COVER ea | af (viii) BETWEEN YOKE AND TANK BOTTOM _I4omm i (ix) BETWEEN L.V. WINDING AND CORE I/3mm i o C) (CLEARANCE ELECTRICALS 5 ° (i) VOLTS (440), MEDIUMAIR > : a - * CLEARANCE 75mm PHASE TO PHASE : ‘55mm. ° PHASE TO NETURAL oO ° : } ° (ii) VOLTS(11000) I CLEARANCE I © PHASE TO PHASE 225mm o |PHASE TO NETURAL 205mm_ ff - [ ° a) Fitting of LOW TENSION Coil sets to the transformer->there are three © following steps in the fiting of the LOW TENSION Coil steps > ° (i) After cleaning the limbs of the transformer core these limbs are © wrapped with the cotton tape so that the stamping of the limbs may not be © displaced from their original position o = ¥ o ° © eee a 9 9090939900999 6-0-0 89008000 090960 90-0 @eeeoo 6) Fitting of HIGH TENSION COIL set of transformer> The high tension coi lis fitted over the low tension coil Separated by press board made cylinder. A decade years ago there was single coil of H.T. set in one limb of Core. This system was changed due to the fact that if fault is found in the H.T. Set then the whole coil has to replace. Now a days we use multi coil H.T. set SO that if one section of coil is damaged then that section is replaced only. 2 cpl core 4 cpl core 6 cpl core 8 cpl core and so on. Here cpl stands for Coils per Limb of core. But it preferred to use 2 cpl cores, 4 cpl cores, and 6 cpl cores. The increase in Coils Per Limb increase the height used for the Tank of the Transformer. This increases the Cost of production and weight of the Transformer Tank. The following steps are involved in fitting the high tension coil B. Press board cylinder is wi C. After this padding of piec Provided for insulation purposes | oO wu a v e0009 »ese09 99066980906 6.9009909 @ 6-6- @eeeodo 4 Inder. Then limb is placed. There may be two coils per mb, may be three, four, six Sight depending on the ‘ating and make of the Wransformer. After each poi the padding and the rings are use described in the step (i), (ii), (iv) F. All the three limbs are completed with the high tension coil sets in the same written procedure 8. MAKING OF CONNECTio} (i) After fitting of both type of coils the high tension coils Sets of each limb in series a| ind whole of the high tension Coils of three limbs are connected in DELTA CONNECTION, (ii) _ After making the High Tension coils of all the CONNECTION the Low Tension side is Low TENSION side is m: a limbs in DELTA Made into STAR CONECTION, 9. FITTING OF PRESs Bi }OARD >A PRESS BOARD of thickness 2mm is cut Out from sheet which has the dimensions qual to the Core. Three holes are made on the sheet. The dia to individual limb of the transformer and Upper:channel of the met separated which separates the limbs os the core, ST of the’ holes:is equal | by. the same distance The PRESS BOARD Performs two following functions > of the PRESS BOARD is to isolate the Coils of the UPPER CHANNEL, (i).The main function transformer from the (ii). The other function of the press board is to Provide a solid base.on which the UPPER CHANNEL will rests, . 10. FITTING UP OF STAMPINGS OF UPPER YOKE OF THE CORES GEUUKUuG ua q 2.2.2.4.2.9 @u Ou 0, 940,9,,9, 9,9, 9,9, 9,999 ,0:9,9 9999999900000. | C90 CrGyeadeGsdid d d uu uu uu In this step of repair the stampings of the upper yoke is fitted back and the core of the transformer is completed. This is done to provide a complete Closed path to induced magneto motive force (mmf) to circulate ong form a electromagnet for the working of transformer. The fitting of stampings needs a accurate experience. The stampings are first cleaned and the fitted on the limbs. There are to type of stampings according to their size. (i) Single piece stampings. This stampings join all the three limbs at a time. (ii) Two piece stampings. This stampings joins the limbs separately. First part joins the limb 1 and limb 2 and other part joins the limb 2 are limb. 3. There is no effect of type of on the working of transformer. These are made to save the material and reduce the wastage. Stampings is a difficult Job. Air gap and tightness of the stampings is considered ot © time. Good fiting plays an important role in working of transformer by the facts that it reduces the IRON LOSSES and increasing the efficiency.” 11.) FITING OF:UPPER CHANNEL > 12) T.T.R TESTS) This test is done on the transformer to (@. verify the number of turns in coils. {i}, Identifying the similar ends of the coils of the three limbs or finding the correct polarity of the coils. >, , P, >, >, > a KK) a >» A u m8 “a u lect 9 90 0,0 0.0.9 UduuuGUUYU 20090 Bee0e000 rpuuvuvuuuugud DETAILS OF COIL FABRICATION SECTION There are so many conditions which must be fulfilled for producing the HIGH TENSION and LOW TENSION coil sets for a transformer. These conditions are as follows 4. all the dimensions of the coils must be according to the make of the transformer. 2. all the sets of the HIGH TENSION and'LOW TENSION coils of one transformer must be fabricated one worker and must be on the same coil fabrication machine this is done so that the tension in all sets of coils could be achieved the same. This section of the transformer repair workshop is the most important in all sections. In this section the metallic wires rolls are converted into HIGH TENSION and LOW TENSION coil sets. This Coil Section is very important be there are only three Coil Sections in Punjab. And this Coil Section of Amritsar provides the coil sets to many transformer repair workshops. The coil fabrication section has (i) 15 HIGH TENSION COIL FABRICATION MACHINE SETS These machines are used to fabricate the high tension coils sets. These machines have an instrument called TURNO-METER. This instrument keep chéck ‘on the number of turns required for the coils according to the Tequirement. The electrical machine used jin the HIGH TENSION COIL FABRICATION MACHINE is of type These machines have higher speed than that are used in LOW TENSION COIL FABRICATION MACHINES. The electrical machine is connected to a GEAR BOX. This GEAR BOX has a contro! paddle. GEAR BOX slow down the speed of the electrical machine to the require speed to. wound the coil. The figure no.1. shows the HIGH TENSION COIL FABRICAATION MACHINE SET. (ii) 17 LOW TENSION COIL FABRICATION MACHINE SETS” These machines are used to fabricate the high-tension coils sets. These machines have a instrument called TURNO-METER. This instrument keep check on the number of turns required for the coils according to the requirement. The electrical machine used in the LOW TENSION COIL FABRICATION MACHINE is of type These machines have low speed than that are used in HIGH TENSION COIL FABRICATION MACHINES. The electrical machine is connected to a GEAR BOX. This GEAR BOX has a control paddle. GEAR BOX slow down the speed of the electrical machine to aun a a bos 59990090003 a a PPPPRS IC? OP PP?P the require speed to wound the coil. The figure no.2 show the LOW TENSION COIL FABRICAATION MACHINE SET (iii), ONE BUTT WELDING MACHINE Butt welding machine is used to weld the two strips of the LOW TENSION coils. This welding set is of A.C. welding type. The condition of welding arises when the strip broke down or the strip finishes before completing the required number of turns in a particular set of LOW TENSION COIL. This type of welding is used because this welding is clean and smooth This makes the coil set even and smooth (IV) ONE ELECTRONIC WEIGHING MACHINE This machine is used to weigh the coil sets to keep the record. (V) SOLDERING SETS = These have the same function as that of the BUTT WELDING. But this is used in case of HIGH TENSION. This is because the wire used in the HIGH TENSION coil is very thin to weld. VI) MEASURING DEVICES these include (a) The Stainless meter scale. () verniar caliber. WINDING OF HIGH TENSION COIL SET When a set of HIGH TENSION COIL js to fabricated then a slip of some dimensions or data is given to the WINDER (WINDER is the worker who winds or fabricate the coils). The slip given to the WINDER includes the a) Make of the transformer (manufacturer of transformer). b) Internal Diameter of the coil (I.D.), a This is usually in millimeter (mm) ¢) Outer Diameter of the coil (0.D.). This is usually in millimeter (mm) d) Axial Length of the coil. This is usually in millimeter (mm) ) Number of turns in the coil. > 0 0 =) a “ever aus a o my o e ° oO - ° ° a ° e eo ° °o uguUudU y 2) f) Size of the Wire to be used. This is usually in millimeter (mm).There are two brands of type of wire used in the making of HIGH TENSION COIL. OPC Wire | this wire is called DOUBLE PAPER COIL. This wire has two covering of insulation paper. If the wire size is say 0.35mm and it is DPC Wire then it will be represented as 0.35 DPC. LAMINATED WIRE. There is no insulation paper covering. This wire is laminated only, NOTE There will be a difference in the dimensions of the coil if we use the DPC or LAMINATED COIL. The OUTER DIAMETER is decreased by Smm and AXIAL LENGTH and INTERNAL DIAMETER is increased by Smith for the same number of turns in the coil for a transformer. But this is compulsory that in Particular transformer all the HIGH TENSION COIL Sets are winded by using same type of wire. Rating of the transformer for which the coil is been fabricated. j Steps of fabrication of HIGH TENSION COIL ‘ Firstly‘the WOODEN SPINDLE of cylindrical shape is load on the machine and a big roll of wire of given size is loaded. The. length of the cylindrical spindle is equal to the AXIAL LENGTH of the H.T. Coil. the OUTER DIAMETER of this is slightly less than the INTERNAL DIAMETER of the H.T. Coil. a After this step a PRESS BOARD of thickness 1mm is wrapped.on the wooden. cylinder. This PRESS BOARD is wrapped till the Outer. Diameter: becomes equal to the Internal Diameter of the H.T. Coil. The layers'of the Press board are stick with the adhesives (usually fevicol is used for this:purpose). | - Then cotton tape pieces are being stick on the Pressboafd along. axis direction. These pieces are much longer than the axial length of the cylinder. These tapes are then folded on the surfaces of different layers. This is done to hold the different layers tightly. When the required internal diameter is achieved then the winding of the wire on the cylinder is started. The first and the last turn of each-and every layer of H.T. coil set is wrapped with insulation paper of thickness 0.05mm. This is @e00000000099000090000909099339990030003 Bie! icuoluilu uy ululoturubundyOpUBubaPuLGiulule ueiu ule glenul a ully vu i \ done to provide insulation between two layers. After specific number of turns the tape pieces are folded to hold the layers together. >) When the specified number of turns is recorded by the TURNOMETER, the winding is stopped. Then the Outer Diameter of the coil set is measured. 6) After completing the winding the coil set is separated from the Wooden Cylinder and the coil is weighed and record is given to the Store Keeper. NOTE the tension provided to the wire by the winder is kept same. WINDING OF LOW TENSION COIL SET the winder of the LOW TENSION coil is also provided with a’SLIP which includes the following dimensions - ae a) Rating of the Transformer, With the rating of transformer in kVA the number of strips to be wound at a time. For example if the transformer is of 100kVA and the number of strips used at a time is 4 then it is written as 100/4- : —s b) Name of the rare fonmer (make of transformer). c) INTERNAL DIAMETER of the coil. a {tis in millimeter (mm). d) OUTER DIAMETER of the coil. It is given in millimeter. ¢) AXIAL LENGTH of coil. Itis given in millimeter. 1) STRIP SIZE to be used. Itis given in square millimeter. Strip size is similar to the wire size incase of HIGH TENSION. This is called as strip because the cross-section of the LOW TENSION Wire's in. rectangular shaped. A strip is used to make the LOW TENSION COIL Set because there is a heavy current in the Low Tension side of a transformer. So we need a larger cross-section area of wire to make the ohmic loses less. That is why aa 0 t 999990980008 > > =§-§--9-9-9-9-9-9-9-9-9-9-9-9- 99-09 990000 vuvvuevuvvvvv4OU0GdOdIVNUUUUHYHUUUULB4et we use the strip which has larger cross-section area. And due to its specia shape it can be easily wind and smooth coil can be obtained. If there are two strips to be wounded at a time then the strips are overlapped on each other. If there are four strips to be used at a time then two pairs of overlapped are formed and these pairs are wounded side by side at = time 2) CHIP Size to be used during the winding. This CHIP is a PRESS BOARD piece of shape trapezoidal with two right angles. It is long enough to wrap around the ends of layers of the Low Tension Coil. Five or six of such pieces of press board are wrapped side by side with that portion of the strip which is wound. in the first and last turn. These strips are used to avoid the damaging of Low Tension Coi during carrying and handling of coil. This damage is called puncturing of coil , The trapezoidal is is given to the strip so that it may set fit in the end of layer and the cross-section of the Low Tension coil may get smoothness. The following diagram shows the CHIP i STEPS OF WINDING OF LOW TENSION COIL SET a) Selecting the Wooden cylindrical spindle and strip size a wooden spindle of axial length and roll of given strip size are loaded on the machine. b) making the diameter of spindle equal to internal diameter U u G4uUbbUUUUbUEUyguUBLuLs4 U0 0-0-0,0-9-9009009999999808900% 8 Fy FW WVU 20 GU 2G2G?2G? re A pressboard of accurate thickness is wrapped on the spindle and adhesives are used to hold the press board and to stick the strips to the press board c) selection of number of strips used at a time the number of strips used is written on the slip given to the winder. The number of strips used is based on the kVA rating o the transformer and also on the MAKE of the transformer. 2, 4, 6, 6 strips are used in pair of two. d) winding of LOW TENSION COIL set the required number if strips are taken in air of two and wound side by side Every five or six turns the turns are hammered with a wooden hammer to make the layer and coil smoother to fit. When the required number of tums is recorded by the TURNOMETER then cotton tape is wrapped on the coil set. Outer diameter is measured which must be approximately equal to the given in the sli. Both the ends of the coil are taken outside the coil set and marked, . After this test is performed on both type of coils, This test is called 1-1, test. This stand for Transformer Turn Ratio. This test is done to verify the number of turn in the coil and also verity hat the coil is not short eirculted. All the coil sets are then marked with: their respective make of the, transformer and all these are send to the Coil store of the workshop, Coil Fabrication Section of this workshop provide the fabricated! coll gets to all most all Transformer Repair workshops in Punjab because there are only three Coil Fabrication Section Departments in whole Punjab, Go Sr.No. Specifications Make, Rating 1 &cpl-- PME 100/4 Case ouoddcududuuuvu sy DT ae = od 0-0-0-9-9— u duddudu gdd ©0000 0 0 or) 2 a Make, Rating &cpl — i Make, Rating &cpl — for H.T. 1D. -- 176mm 0.D. ~ 250mm Axial ~ Wire Size — 4.7DPC JE. 100/4 Axial -- 90mm Turns -- 750 Wire Size 1.6DPC «>: TA. 100/2 conventional for H.T. 1.D. -~ 178mm O.D. -- 240mm 74 Strip Size - (10.6*4.35)? Chip size ~ 65mm? layers 2 Tums = 67 Stiip Size=- | - * (15x5)2- Le Chip size — 75mm? Layers— 2 a G 9909009003 G Gu Axial -- 187mm Turns -- 1672 Wire Size -- 1.6SE Axial 410mm Tums-- 76 Strip Size -—- (9.5%4.75)? Chip size ~ 90.2mm? Layers 2 9.9 ° 0. 2. 2. 2. - 2-2-2 9-9-9 -9 > 99949 2595999,9,9. D 0.000000 0 wuuuuvuutuJs vuudsds C. CORE OVENING SECTION After performing TRANSFORMER TURN RATIO TEST on the newly prepared core the core is given to the CORE OVENING SECTION for removing the moisture in the core. Why the OVENING is done? The Ovening is to remove the moisture and increase the resistance of the coils. Moisture decreases the resistance by providing a path of less resistance to the Current. The reason of getting moist in the core is that the Transformer Core remains open in workshop during the repair for long time. The materials used in the repair of the transformer repair like the PRESS BOARD, INSLATION PAPER, HIGH TENSION COIL SET & LOW TENION COIL SET, H.T. &L.T. BUSHES, etc. are made of such materials that absorb the moisture from the environment, This moisture’ -- has to remove from them for good efficiency of the transformer: For this purpose there is necessity of ovening of the newly repaired TRANSFORMER CORE. And for this purpose there are four big OVENS in the TRANSFORMER REPAIR WORKSHOP No. 2. _ These Ovens are run at 80 to 85°C according to the manual or according to the standards made, But in TRW these are run at 150°C to decrease the time of running the Ovens. As given by the “standards”, the Transformer Cores must stay inside the Qven for about 36 hours but according the load of the work they put the:trarisfofmers inside the Oven for 12 hours for first time and then Megar Testis performed in:the la after cooling the Core with Dry Hot Air. Ifthe Megar Fest Result not. - satisfies the Standards then the Core is again send to Ovening Section and Ovening is done for about 8 hours and then again Megar Testis performed, This process is repeated for number of times till the Megar results are not up to the mark and whole the moisture is removed. if moisture is not removed while doing HIGH PRESSURE TEST; the transformer will burst up and can cause great damage because of short circuiting inside the core. 288090000699 S9G 0499 OHSHT0T29900F 0090008 2 2 2 2 3 > > S ° 2 2 =) 2 > 3 >. let for the hot air from the OVEN after use. e. TEMPERATURE MEASURING GAUGES - there are three temperature measuring gauges. These gauges are analog in type. The basic principle of working of these gauges is EXPANSION OF MEATAL ON HEATING g. MAIN SUPPLY BOARD - this board consist of fuses, MCBs, ON-OFF switches, etc, The board gets THREE PHASE SUPPY. The OVENS are protected by use of OIL CIRCUIT BRAKER. The THREE PHASE SUPPLY to the OVENS is taken directly from the OUTPUT of DISTRIBUTION TRANSFORMER OF 500KVA provided to the TRANSFORMER REPAIR WORKSHOP No. 2 h. MAGGER TESTING BOARD — A BOARD called MAGGER TESTING BOARD is provided to the OVENS on the OUTER SIDE of the OVENS. This BOARD consists of three types of terminals. H.T. , L.T. and EARTHING terminal. There are six terminals of H.T., six terminals of L.T and one of EARTHING. One-one terminal of each-CORE placed in the OVEN for heating purpose is connected to these terminals. This is provided to perform the MAGGER TEST on the Transformer Core during heating without opening the DOOR of the OVEN. MAGGER TEST is very compulsory tf make the TRANSFORMER CORE fit for rest of the tests in the TESTING SECTION. There are following steps involved in the CORE OVENING SECTION. A.MAGGER TESTING — before heating the Transformer Cores in the OVENS, a MAGGER TEST is performed on the Transformer-Core. This test is performed with help of RESISTANCE: MEASURING - INSTRUMENT called MAGGER so called MAGGER TEST. In this test resistance is measured between the H.T. &-L.T:, H.T. & EARTH and .L.T- & EARTH. RESULT of the MAGGER TEST ~ a. if the resistance is, ZERO ohms then there is short circuiting of coils. If the résistance is more than 100 ohm then the Transformer Core is kept in the OVEN for heating B. HEATING PROCESS — The Transformer Cores are placed on the BASE of the OVEN and the BASE is pushed in the oven. Then the one-one terminal of each core is connected with the TESTING BOARD. terminals for INTERMEDIATE MAGGER TESTING of the Transformer Core. -o,0 009908900099 909099899098 9 0] a a a The HEATING of the Transformer Core is done at least for 36 hours. This HEATING is carried out till the Transformer Core gives the resistance of minimum of 500 ohm. It should not be equal to ZERO. C. INBETWEEN MAGGER TESTING ~ after 18 to 24 hours of continue heating of Transformer Core, once again the MAGGER TEST is performed on each Transformer Core undergoing the HEATING PROCESS. This is done so that if the required resistance is achieved then the heating is stopped and next step of the transformer repair is performed on the core. ir D.COOLING OF CORE — during the heating the temperature of the Transformer Core may rise to 150°C. This high temperature is not workable so the Core is cooled with blowing DRY AIR on the hot Core. This is done with the help of a heavy fan. This big fan has 3-phase induction motor. E. MAGGER TESTING — after the Core has beef cooled to the workable temperature then once again the MAGGER TEST is performed on each Core, The MAGGER TEST is explained in details in the TESTING SECTION. i If any of the Cores does not satisfy the given value of resistance the Core is again placed in the OVEN for more time ‘so that the resistance is maintained. Ifthe Core gives the zero value of resistance then this means that the Coil set is shorted and the Core is giveit back fo the:CORE REPAIR: SECTION and the same FITTER will work on the failed Core. The other materials and equipments which come for the removal of moisture are Coils of Relays. Current Transformer and Potential Transfoimers. Power Capacitor of Capacitor Bank of Distribution ’Sub- stations. Lightening Arrestors Silica Gel H.T. & LT. Bushes. HT. & LT. Coil sets. Press Board and Insulation Paper. 909000000608 “uuu 9° wu a GUUuUuCuuGuG 2; eo0 95995979 ;9,,9 ,? BE tee Set gy tie D. BOX-UP SECTION In the BOX-UP Section the Transformer core is fitted in the TRANSFORMER BOX. This is only done when the Transformer Core satisfy the MAGGER TEST Results i.e. the Resistance of the Coils must be more than 500ohms. STEP1. The Base of the Transformer Tank is.covered with a-Press BETWEEN H.V. winding and T/F TANK J (i) NON-BUSHING SIDES ][25mm (ii) BUSHING SIDES |[4omm | i Board of 5mm thick. This Press Board is placed so that the Lower Core Channel andthe feet of the Core do not touch the Transformer Tank. If this happened then there may be danger to the operating working ‘STEP2. In'this step the Transformer Core is lifted with the Crane and placed inside the Transformer Tank. At this the INTERNAL CLEARANCES.CHART issued.by the [:S.1. is considered. During the fitting of Core the-following.Glearances are- considered — c 7 The space left is filled with the Press Board of thickness 1.5mm:- This Press Board performs two functions. First, itfills the extra gap and Second it form a Insulation Barrier between the Transformer Tank and the HIGH TENSION Coil sets. ager Re STEPS. after fitting of Core the Transformer Tank and the Transformer Cover is prepared for box-upping. In this step the Bushes of both types are fitted, Firstly the bushel of rubber is fitted, and then the H.T. Bush is fitted on the BUSH CLAMP. Alll the screws of the BUSH CLAMP are Screwed equally so that the Bush may not crack due to one sided pressure, The L.T. Bushes are directly attached to the Transformer Tank. STEP4. After bushes have been fitted on the Box and cover the H1.T. <. coil ends are connected with their respective Bushes : STEPS. After the connections are made, a CORK SHEET GASKET 's cut whose dimensions are equal to the dimensions of the face of the transformer Box and the Transformer Tank. This CRK SHEET GASKET 990090990080 > is sandwiches between the Box and Tank cover. : The function of the Cork Sheet Gasket is used to make the . interior of the Transformer air tight. The presence of air will provide a > leakage path to the mmf and this will in turn weak the electromagnet. This will affect the efficiency of the Transformer. > Oe oe 19,0 ,0.0.0 ©0009 © © 2900 [ @.4.4.40.8 0.0, 9, 9,,.9,,0,,9, | G G STEP6. At last the cover Box with help of Nut-Bolts. of the Transformer is fitted on the Transformer | eo za el 2 Sr.No. | Temp. H.TALT. HTJE. LTE. Cu AL | ra 5 10 1600/7060 | 1600/700 | 800/200 | 1.265 1.270 Al 2 L__2. 11 1520/665 | 1520/665 | 760/190 | 1.260 1.265, 3 3. 12 4400/630 | 1400/630 | 720/180 | 1.255 1.260 d | 4. 13 1360/595 | 1360/595 | 680/170 | 1.250 1.255 d > 5. 14 1280/560 | 1260/560 | 640/160 1.245. | - 1.250 > 6. 15 1200/525 | 1200/525 |-600/150 | ~ 1240. | 14:244 || ad ir 7. 16 1120/490 | 1120/490 | 560/140 | 1.235 1.240 d 2 8. 17, 1040/455 | 1040/455 | 520/130 | 1 .230 1.234 2 9. 18 960/420 | 960/420 | 480/120 1.225 1.229 ad of 10. 19 880/385 880/385 | 440/110 | 4.220 1.224 = 11 20 800/350 | 800/350 | 400/100 4.216. 1.220. d 2 412 21 760/332.5 | 760/332.5 | 380/95 | 1.211 4.215 d 13, 22 720/315 _| 720/315 | 360/90. 1.207, 1.210 2 14 23 680/297.5 | 680/297.5| 340/85 | 1 .201 1.205 d iL. 15 24 640/280 | 640/280 | 320/80 1.197 | 1.200 d — 16 25 600/262.5 | 600/262.5 | 300/75 1.193 1.196 > 17 26 560/245 | 560/245 | 300/75 1.188 | 74.191 4 18 27 520/227.5 | 520/227.5| 280/70 1.183 4.187, d > 19 328 480/210_| 480/210 | 260/65 1.179 | 1.182 ia) 20 29 440/192.5 | 440/192.5 | 220/65 1.174 | 1.178 a ere) © 2 k © 3 = e 2 £ 2 oe > Se oO 2 f 2 * ° °3 e S) 2 £ 2 eo > e 2 e id e ; e > ° ° a ° @ ° ° ° ° 6 7 © @ @ oe oO « 6 6 6 6 6 o © oe oe e o o @ @ @ e ° e@ E. TRANSFORMER OIL DEHYRATION & FILTRATION SECTION The Transformer Oil Dehydration -& Filtration Section of a Transformer Repair Workshop is very important section. In this Section as the name suggests, the Transformer Oil is dehydrated and filtered The Oil of the Transformer plays an important role in proper working of the Transformer. The fact for this saying is that Transformer Oil is only medium of contact of each and every interior part of the Transformer with each other and even with environmental air and surrounding of the Transformer. FUNCTIONS OF TRANSFORMER OIL. Transformer Oil provides insulation between all the interior parts of Transformer. Transformer Oil serves the function of COOLANT in Transformer. It absorbs the heat produced in the Transformer due to HEAT LOSSES and throws it to the Natural Sink that is Environment. The hot Oil rises up and.cooled inside the Radiators and cooled Oil goes down to the tank. Transformer Oil extinguishes the shark produced during the short- circuiting of cols and prevents the further burning of coils and stampings of the transformer. Transférmer Oil also acts as DIELETRIC MATERIAL inside the Transformer. ie é Transformer Oils are the chemical compalind of type Askerel. These are Dichlorinated Compounds. The most important propeities of ° Transfcrmer Oil are as follows — ’ Transformer Oil has very high Diele¢tric Strength. Transformer Oil is not an absorbent of moisture. * Transformer Oil is a good Heat Absorbent and good conductor of heat. Transformer Oil is bad conductor of Electricity. Transformer Oil has high Boiling point and high evaporation or vaporizing point. Transformer Oil has low viscosity. Why the Oil dehydration and Filtration Set is required? During opening of the container of transformer oil, there may be addition of impurities like moisture and vapours. The presence of moisture or vapors of water decrease the Dielectric Strength. So it is compulsory to dehydrate the Oil Also when the used Transformer Oil is to made reusable then it has to made pour. It should be free of carbon vapours, moisture, pieces of insulation paper. These whole things are done by dehydration and Filtration Set This set heat the Transformer Oil and filters it TRANSFORMER REPAIR WORKSHOP No. 2 has three Dehydration and filtration Sets and one Oil Storage tank. ie STORAGE TANK — The storage tank has capacity of 1500litres, It is made of iron. The design of the tank is special i.e. it is tapered at an angle. This is so done so that the heavy impurities like iron pieces, Press-board pieces and crude oil may settle down at bottom. These materials are extracted out from the tank through an opening at. the tapering side. This Storage tank has two opening, One for Inlet and second for the Outlet. Inlet opening is joined to a Sucking Pump. This pump sucks the Oil from the Oil drums and from the Transformer Tanks. The Outlet opening is joined with the Inlet of Dehydrating Set. DEHYDRATING & FILTERATION SETS — There are three Dehydration and filtration sets in T.R.W. No: 2. ‘These sets are used for making the Transformer Oil frée frommoisture, impurities and filter it. i This set consist of — TANK - this interior of the tank is made of iron alloys. This metal. - sheet is then wrapped by:Glass Wool Coating. The Glass Wool Coating: acts as heat Insulator. This is provided to check the heat losses during the heating of Transformer Oil The tank consists of many opening. These opening are — Inlet Outlet Opening for pressure Testing Oil opening The Inlet and Outlet opening have filter for filtering the transformer oil. These filters are fitted inside the taps used on these opening. The oO ouud Gu 2,9-2.820208929900900900090 vu dUUGduUUVINN vuuuuuuvuuTuuuudd ~ placed in ~~ bend when it is red hot. filters are replaced after some thousands of liters of Transformer oil has been filtered and cleaned at regular time interval. Testing Oil opening ~ this opening is used for taking out the Transformer Oil for testing. The Transformer Oil regularly checked for its required Dielectric Strength. A sample of Oil from in between heating is taken and sends for testing its dielectric strength. The sample is sends to the laboratory. This laboratory is inside the T.R.W. NO. 2. THREE PHASE INDUCTION MOTOR ~ there is a three pliase induction motor of 440V. This motor is to drive the vacuum pump, Inlet and Outlet Drain valves. VACUUM PUMP ~ this Vacuum Pump is provided to suck the air inside the Heating Tank. These are V-type vacuum: HEATERS — There are 12 heaters in small set and 18 heaters in bigger set. The sets have different capacity of Oil heating, The heaters used in smaller set are of 1.5 kW rating and that of used in bigger heaters have 2.77kW capacity. These heaters are Supplied with Three-phase supply. Each phase is loaded with eight | heaters in case of smaller sets and ten heaters in case of bigger sets. All the heaters used in all Dehydration & filtration sets are of ROD-Type heater. The filament is made of tungsten metal. “The type of heating used in the Setis Indirect Heating. The heaters are not in direct touch with the Transformer Oil, The heaters are Rater Pockets. Heater Pocket is.a pipe of suitable length and this is made of. The main reason for using this material.is that it does not ¥ - The Heater pocket has more function té do: This function is to act as second terminal for the Level Alarm. When the oil level inside the Tank is falls to certain fix level then Alarm blows. Production of heat in the heater is based on | square R. CONTROL PANEL ~ The Control Panel consist of Fuses for three phases Starter for the Motor of the set Starter for Heaters Protection devises for set like MCBs and Circuit Breakers Auto cut devise Timer + Temperature setting instrument Pressure setting instrument 2 0 8] Og S VUUUOUKBUOUUUL)O @ee8000600080 dddddddduu 98009 0.9,0.2.8.8.8 089 uuu €@eo000, vuudd ou oS PROTECTION PANEL ~ As these Sets are costly and their continuity of operation is compulsory. So to protect them from surge current and voltages is necessary and they are work on three phase supply. These sets are protected by Oil Circuit Breaker. The rating of these Circuit Breakers is Capacity 400-415V and breaking capacity 0.3 pf. - ~~ and Making Capacity 62.5kA. Short Time Current is SOKA in 1 seo. FILTER ~ There is a series of filters in each set. These filters remove the waste of the oil after heating process. MEASURING GAUGES - there are so many measuring gauges fitted on the Tank of the Dehydrating and Filtration Sets. These include the Temperature Measuring Gauge, Timer, Pressure Measuring Gauge, ALARMS ~ there are different alarms for the safety of workers and sets. These are + Pressure alarm Fire Alarms Temperature Alarm PROCEDURE TO DEHYDRATE AND FILTRATION OF Transformer Oil There are two types of Oil which is to dehydrate and filter. Distribution Transformer Oil io LTS Power Transformer Oil ; : The Power Oil is used in the Power Transformers when it is fresh. But when this used Oil is not able to serve its function in power transformer then this Oil is used in the Distribution Transformer. Power transformers are the transformers whose Input Voltage is more than 11000V. The Transformers who's Input Voltage is less than 11000V are called Distribution Transformer. When the transformer is dismantled then its-Oil is poured in a drum and this Oil is tested. If this Oil satisfies the required conditions then this Oil is filled in the Tank of the dehydration Set. e-0-0-9-0-9-0 Ox Onda De 9-9-9 Ss 3 3 2 » > 2 2 5) ] 9 2 s 4 2 The Thermostat is set at 85°C. The vacuum Pump is switched on and the supply to heaters is also switched on The Timer of the set is reset and set for new interval of at-least five hours. After the time limit, a sample of Oil from the tank is taken and is sent for Oil testing Lab. If the sample satisfies the conditions then Transformer Oil is considered OK and is ready for filling in the transformer. Single sample of the Transformer Oil is tested at least four times. Ifit fails in single turn the sample is considered as faulty and the set from where it has been taken is restarted. a Fe The Oil is considered OK only when it satisfies the required condition of Dielectric Strength more the 40kV. TRANSFORMER OIL TEST As discuss earlier Transformer Oil is the only medium that make touch each atfd-every interior parts of the Transformer. So it necessary that Transformer Oil should hold each property that is required-for the any chemical property. The main properties of transformer Oil-are’as following — 5 : a Transformer Oil has very high Dielectric Strength. Transformer Oil is not an-absorbent of moisture.» 79.5 04a Transformer Oil is a good Heat Absorbent and good conductor. of heat. me ny Transformer Oil is bad conductor of Electiicity, --2 = Transformer Oil has high Boiling point and high evaporat vaporizing point. Transformer Oil has low viscosity. The Transformer Oil is mostly tested for its Dielectric Strength and moisture content if this Oil is fresh oil. Both these conditions are judged by testing the Dielectric Strength of the Transformer Oil. ‘A sample of transformer Oil is taken from the Dehydration & Filtration Set and it tested in the Transformer Oil Testing Set. 22229) ©UVUKUUUUUG8 4 020 DD 2 duuuu -0.-0..0..0,.0 d 1) 2) Poured in it. ) 1) DETAIL OF TESTING SET. The testing set consist of following parts — Testing Container — The Testing Container is made of Glass or Fiber Glass. One pair opposite surfaces of this container has two conducting knobs called Conducting Contacts. The gap between there knobs is adjustable . a Testing Chamber ~ This testing Chamber has two terminals of Single- Phase Step-up Variable Transformer. This Chamber ig covered with a glass lid Trip Relay ~ This relay is connected in series with the Testing Container. This relay trips when the dielectric strength of the Oil breaks, Voltmeter — A Voltmeter is connected on the secondary sidé. This Voltmeter records the Voltage at which the Oil had its break down. Gischarging Switch — There is Discharging Switch which must be switch on and Off after testing is completed. i : Working Instructions for Oil Testing Equipment : i a aa There should-not any bobble formationin ths Wash the Testing Chamber and make] The electrode gap must be adjusted with measirring-gauge: tt should be 4mm for Distribution Transformer Oil and’ > Gren incase of Power Transformer. Procedure of Testing — 5s % Adjust the gap of the electrode and fill the testing pot with sample Oil to be tested such that electrodes are dip inside the Oil. Place the pot onthe H.T. hors, Let it rést as per IS: 6972.72. Connect the main leads to the 240V A.C, Mains and E" (earth) terminal to nearest Earthing Switch ON the Mains. Increase the voltage slowly til the flash does not appears. When the flash appears the trip relay automatically operate, Note the recorded voltage by Voltmeter. Repeat the process four or six times Mila dd a i > G. WELDING SECTION When the Transformer is passed by the Testing Section, the Transformer is send to the Welding Section. In this section Transformer Cover is welded to the Transformer Tank. Small strips of iron metal are welded on the cover and tank. This welding act as Seal to the-lock and make the security of the transformer stronger. : Another function of the Welding Section is to weld the burst transformer if the Stampings of burst Transformer are in working condition When there is leakage problem in the tank, conservator tank or radiator, then gas welding is used for welding There are three welding sets. They are A.C. welding set, D.C. welding set and Gas welding set, 0099900909899 88 BBP 8RPB8?5 H. PAINTING SECTION In this section the look of the Transformer are improved by painting its Body and the H.T. &L.T. Bushes with the standard colours, The Transformer Tank or outer body is painted in Grey paint only. The body of the Transformer is painted with Spray gun’ there me paint Spraying set present in the T.RW. No. 2. This set consiste’ of a compressor, spray gun and paint tank The three phases of H.7. side are painted in red, yellow and blue Golour. The red phase is on extreme left then the yellow and then on extreme right it is blue phase. The four terminals of the L.T. side are also painted in fed, yellow and blue colours, The neutral terminal is painted in Black colour. When one faces the L.T. sine of the Transformer then the red phase is on extreme left, then yellow and then it the blue. The neutral is on extreme right. After Painting the Transformer is send to the Testing Section for final testing. 22 99.92.22: 0.8 GUVFOEVOSEVUIGUUOU DOU DD ©-9.9-0-9-9-9-0-090909999999990000909 bv doug 3S VOLTAGE REGULATION IN TRANSFORMERS The change in secondary terminal voltage expressed as a percentage (or per unit) of the secondary rated voltage, when load at a given power factor is reduced to 0, with primary applied voltage held constant, If V2= secondary terminal voltage at any load. ‘And E2 =secondary terminal voltage at no load. Then at a given power factor and specified. load, the voltage regulation.is given by Voltage Regulation = E2-V2/ Secondary rated voltage (in p.u.) As per IS, the secondary rated voltage of a transformer is equal to the secondary terminal voltage at no- load, i.e. E2 Therefore Voltage Regulation= E2-V2/E2 (in p.u.) The change in'secondary terminal voltage with load current is due to the primary and secondary leakage impedances” of the transformer. The magnitude of this change depends on the load pf, load current, total resistance arid total leakage reactance of the transformer; A distribution transformer should have a small value of voltage regulation (ue ‘good Voltage regulation), so ‘that theé-tetminal

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