Transformer Basic

Distribution and
Transformer part in it
Module 1: Basics
Module 2: Major Transformer parts
Material developed by:
Jaroslav Kovar
Module 3: COPQ Analysis
Quality School
QS
ABB Australia Pty Limited
Module P1 Slide No 1
Goals...
Objectives... Competencies...
Explain basics about Knowledge of transformer
transformer function function
Understanding COPQ Basic understanding of
defect costs
Importance of defect Prevention techniques
elimination Workplace organisation
Understanding the key
role of workcenter within
the manufacturing
process
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Module 1
Basics about Magnetic Field

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Basics...
Types of magnets:
natural or man-made:
permanent S N N S
electromagnet
Magnetic poles
like ones repel each
other S N S N
unlike ones attract
Magnetic lines of force
Magnetic flux (all lines)
Magnetic induction (to
magnetise an object without
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contact)
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Basics...
Magnetic field of force
Magnetic lines of force S N S N

-always heading from North
pole to South pole
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Basics...
S N S N
Permanent magnets
Like poles repel
Unlike poles attract
two magnets create
one
one magnet and one
iron rod - which one is
the magnet???
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Basics...
Polarity of an Electromagnet
Left-hand rule for the polarity
Caution: This is a visualisation technique

only. Do not actually put your hand on the
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coil!!!
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Induction 1...
Three conditions:
Mutual Induction Conductor
No el.connection Magnetic flux
between the
coils Movement
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Induction 2...
Secondary Primary
Switch
Magnetic Flux
DC versus AC current
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Magnetic Field...
Magnetic
flux fi
Laminated
Core
Connection
Primary Secondary
Winding Winding between windings
Magnetic flux
Silicon
Steel
(Low Loss)
Carbon
Steel
(High Loss)
Importance of Material
Air gaps
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Eddy currents and Hysteresis
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Analogy with Hydraulic...
Electric Circuit:
Hydraulic Circuit:
Pump Load Battery Load
20kg
Low pressure
Energiser
Electric current
Hydraulic current
High pressure
The current from the battery flows in
one direction only - DIRECT CURRENT-D.C.
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Analogy with Hydraulic...
Electric Circuit:
Hydraulic Circuit:
Pump Load Battery Load
20kg
+ -
Energiser
Energiser
Electric current
Hydraulic current
- +
Now we will replace the battery with A.C. generator...

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Alternating Current...
Electric Circuit:
Battery Load
+ -
1
0.8
AC Generator Electric current 0.6
0.4
- + 0.2
45
90
135
180
225
270
315
360
-0.2
-0.4
-0.6
-0.8
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-1
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Analogy for transformer...
Hydraulic circuit Electric circuit
High flow
High Current
Low Pressure
LV Winding Low Voltage
Low current
+ -
Small flow
HV Winding
High Presuure High Voltage AC
- +
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Analogy for transformer...
Gearbox in a Car
Chain wheel on Push bike
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Analogy for Transmission...
Voltage ~ Pressure
Current ~ Flow
Resistance ~ Loss of
pressure through the
friction
For Long distances: High Voltage/Low Current ~ High Pressure/low flow
Suitable for Transmission, but not for Consumption
For Short distances

and consumption: Lower Voltage/High Current ~ Low Pressure/high flow
Suitable for Consumption and short distances

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Why do we need a Transformer...
Generating electricity at High

Voltage is not practicable
(generator output is ~6kV)
Transmitting electricity at the
same voltage as generated is
expensive
(too low, high losses due to high
current)
Using electricity at the same
voltage as generated is
dangerous and expensive
(6kV at home?!, all appliances too
expensive )
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Where do we need a transformer...
Generation of Electric Power
Power Transformer (up)
Transmission of the power
PowerTransformer (up/down)
Distance and transmission
voltages
Losses on transmission
Distribution
transformer (down)
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Transmission line...
6-12kV 300-765kV
123-245kV
36-72.5kV
Distribution
Substation
11-33kV
433V
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Why do we need a Transformer...
To convert electrical energy from

one Voltage level to another
Note: Transformer does not change the frequency! Relative size of Conductor
for same power rating:
Example: 1 phase
10kVA transformer
Crosssection
Primary 11000V, 0.91A: 40times
11000V*0.91A=10000VA=10kVA bigger
Secondary 250V, 40A:

250V*40A=10000VA=10kVA 11000V 250V
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Module 2
Major Transformer Parts

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Transformer function parts...
Core
Coil
Tapswitch
Bushing
Tank
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Transformer Core...
Made from Core steel

laminations with insulation to
restrict currents flowing Crossection:
through
Laminated Core
If the Core was made from solid
iron block, this would act like a
short circuited secondary coil and
high destructive currents would flow
Solid Iron Block
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Transformer Coils...
Source of magnetic field

I2R losses
Cooling
DDP function
HV and LV winding
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Losses in Transformer...
No Load Loss (Fe)

Eddy Currents in
Total Losses
laminations - loss due
resistivity to current flow
W
within laminations
Load Loss
Hysteresis loss - due to
remagnetisation of moleculs
in alternating current
Load Loss (Cu) No Load Losss
I2R Loss due to current flow

through the winding with
resistance
Eddy currents in conductor 0 I
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Ratio and Tapswitch...
No of turns on HV side
No of turns on LV side
Conductor size on HV side
Conductor size on LV side
V1 N 1 I 2

V2 N 2 I 1
kVA same for both sides:

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V1*I1=V2*I2
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Ratio and Tapswitch...
Rating plate
connections:
Winding connection
HV voltages
Tapswitch positions
LV voltage
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Bushing...
Mechanical function
Electrical function
Sealing function
The most fragile part...
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Tank...
Protection of Transformer
function parts
Cooling surface
Presentation of our
workmanship standard
overall appearance
paintwork
stencilling
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Transformer Oil...
Important aspect of
transformer service reliability
Insulation
Breakdown strength
Flash point
Water content
Cooling
Viscosity
Long life
Resistance to ageing
Colour and appearance
Dielectric Dissipation
Factor (DDF)
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Cooling...
Oil cooling
Air cooling
O - Oil
Inside of the Tank
Natural cooling
Forced cooling
N - Natural
A - Air Outside of the Tank
N - Natural
ONAN, ONAF
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Oil Conservator and Breather...
Conservator takes up the

changes in the oil volume
due to different
temperatures
Breather allows
transformer breathe dry
air when the temperature
goes down
filled with silicagel
blue when dry
light red when saturated
with moisture (can be
reprocessed)
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Buchholz relay and Explosion
vent...
Gas-detector relay
(Buchholz)
positioned in pipe between
the tank and Conservator
Usually two functions:
Minor fault - fault indication
Major fault - switch off the
transformer
Qualitrol
protects transformer against
pressure damage due to
flashover or short-circuit
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Rating Plate...
Rating Plate:
Kind of transformer
Standard number
Manufacturers name
Serial number
Year of manufacture
Number of phases
Rated power
Rated frequency
Rated voltages
Rated currents
Connection symbol
Short circuit impedance
Type of cooling
Total mass
Mass of insulating oil
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Quality Factors...
No damage on any part of transformer

Insulation
No foreign particles
Dry
Correct clearances / insulation thickness
Coils
correct dimensions of conductor
correct number of turns
correct connections and winding direction
good conductor joints
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Quality Factors...
Core:
Good magnetic circuit:
minimum air gaps
no strain on laminations
no edge burr
no waves
Core Coil Assembly:
good mechanical strength
packing tight
bolts tight
no loose items
Tank:
good welds
no leaks, reliable gasket joints
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good paint pretreatment & finish

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Quality in Production...
Conformance to
requirements:
Following WI (MQOPs)
Focus on the job
Cooperation with others
Keeping Tools in good
working order
Housekeeping
If in doubt - ALWAYS
ASK!!!
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Module 3
COPQ Analysis
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COPQ - Cost of Defects...
What is a
Defect?
Possible causes of defects:
Defective Material
Missing Information
Human aspect
Consequences
Price to be paid...
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Transformer Failure...
Insulation Test Failure Rate
Conductor
Ratio 14
12
NLL 10
Pe r ce nt
8
LL 6
4
Bushing 2
0
1995 1996 1997
Workmanship quality...
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Evaluation model...
PROCESS DIRECT LABOUR PRODUCTION PROCESS OPERATING COSTS TOTAL

OPERATING COST PRODUCTION
COSTS ADDED COST
INDIRECT MATERIAL OH COSTS PER PROCESS STEP ADDED
INDIRECT EXPENSE APPRAISAL COSTS
PC1
PC1 PC2
PC2 PC3
PC3
11 T1
T1 22 T2
T2 33 T3
T3
OH COSTS: PREVENTION COSTS AND EXTERNAL FAILURE COSTS

OH COSTS: PREVENTION COSTS AND EXTERNAL FAILURE COSTS
LABOUR
TEST EQUIPMENT
APPRAISAL
COSTS
MATERIAL CONSUMED
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Sample Defect Cost...
Incorrect Lead Connection: 3. Warranty
Transport unit back
1. Rework +cost as per 2.
2. Test Failure Transport:
3. Warranty 2. Test Failure ~$100,-
Detank unit Material:
Rewind coil 1xcoil~100-200,-
Reprocess Labour:
Tank+Retest 1man 2.9hrs
Material: ~$200,-
1. Rework: 1xcoil~100-200,- Administration:
Open unit and Labour: ~$50,-
reconnect 1man 2.9hrs Total:
Labour: ~$200,- ~$500,-
1man 10mins Total: + cost of Customer
~$12,- ~$350,-
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dissatisfaction...?
QS
Sample Defect Cost....
Profit/Loss for Typical units with Sample Rework
Incorrect Lead Connection: Unit: 10kVA 1phase 100kVA 3phase
Selling Price: 1340 4350
1. Rework 12 12
2. Test Failure 350 350
3. Warranty 500 500
1. %Rework of Price 0.9 0.3
Chart Profit/Loss for Typical Units 2.%Test Failure of Price 26.1 8.0
with Sample Rework: 3.%Warranty of Price 37.3 11.5
1. %Rework of Margin 94.4 96.1
2.%Test Failure of Margin -63.2 -14.9
3.%Warranty of Margin -133.2 -64.2
200.0
150.0
100.0
COPQ 50.0
0.0
LOPQ -50.0
100kVA 3phase
10kVA 1phase
-100.0
-150.0
+ cost of Customer
dissatisfaction...?
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-200.0
1. %Rew ork of Price
3.%Warranty of
3.%Warranty of
1. %Rew ork of
2.%Test Failure of
2.%Test Failure of
Margin
Margin
Price
Margin
Price
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COPQ Analysis...
1997 results - number of Warranty claims raised
Number of CAR/PAR raised during 1997

5
4.5
3.5
2.5
1.5
0.5
0
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Source - CAR/PAR log
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COPQ Analysis...
1997 - Cost of Rework from Warranty claims only
Total Cost $44.122,-

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COPQ Analysis...
1997 - Cost of Rework inside the factory
Total Cost
25000
20000
15000
Total Cost $70.032,-
10000
5000
0
F a ulty F a ulty S upplie r P ro duc tio n De s ign/Eng
e quipm e nt m a te ria l
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COPQ Analysis...
1997 - Cost of Captured Rework
Warranty Cost $44.122,-

R/R/S Cost $70.032,-
Total COPQ $114.154,-
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COPQ Analysis...
1997- Grouping by Cause of occurrence
200
180
160
140
120
100
80
60
40
20
0
Production Faulty Supplier Design/Eng Faulty
material equipment
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COPQ Analysis...
1997 - detail of Faulty Equipment as the most expensive cause
20
18
16
14
12
10
8
6
4
2
0
C o re s te e l c ut re wo rk M a c hine fa ilure B ro ke n s tra pping ba nd B us hing bro ke n
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Workcentres...
Core Cut
Winding
Lacing/Core Building
Core Coil Assembly
Tanking
Testing
Final Assembly
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Core Cut...
Correct material
Condition of Core steel:
Correct width/thickness
No burr
No waves
No damage to insulation layer
Sharp tools
Accurate machine alignment
Accurate number of
laminations
Correct Mandrel/stack height
Laminated Core
This section important mainly for NLL performance of transformer

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Winding...
Correct conductor size and material

No conductor defects
Insulation thickness
Following the winding sheet:
number of layers
number of turns
position of taps
good joints
tight winding
Cleanliness during the whole
process
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This section important mostly for LL, Ratio, Separate Source and Short circuit tests
QS
Lacing...
The main focus is to get the
core steel laced as close as
possible in the same position
as the loop was after annealing.
(use scribe-lines)
Do not throw laminations away
Do not damage the laminations
during the packing process
Air gaps should be minimal (as
per cutting process)
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Core Building...
Correct number of
laminations
No damage:
no burr
no waves
no insulation damage
Correct set up of the table
Correct Core dimensions
Accurate and punctual work
Minimum air gaps
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Core Coil Assembly...
Correct Core/Coil packing

Minimum air gaps on top
yoke
Good clamping
Correct lead connections
Good joints / crimping
Correctly operating tapswitch
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This section important mainly for NLL, LL and Ratio performance of transformer
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Tanking...
CC Assy properly dried out Final step in Assy of the
Tank clean Transformer operating parts
Bushing assembly complete Why is this step so important
and tightened to correct torque Once the lid is on, its on...
All connections tight, no loose
items or missing nuts/bolts
No foreign articles inside...
Clearances on leads
Oil level
No oil leaks
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This section is important for every aspect of transformer performance
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Testing...
Unit complete from tanking,
pressure tested, Job card
signed
Correct information (TDS)
Check the Test details
Check the Standard unit to
be tested against
Issue correct Rating Plate
Correct Serial number
Correct Customer serial
number
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Final Assembly...
Check Tank and paint quality This is the last time we
Bushing and caps in right see the unit
position and aligned next inspection is at
No visible damage on any customer premises!!!
part
All fittings on
Double check Rating Plate
Double check Stencilling
Other applicable marking
Documents complete for ABB Transmission and Distribution
Distribution Transformer Division

Despatch
Approved for Despatch
This Distribution Transformer Product has been approved for
despatch by the undersigned on behalf of the people of ABB
Power Transmission Pty Limited who have participated in its
Sale, Design and Manufacture.
Quality School
Signed by .......................................... Date: ...../...../.....
QS

Transformer Basic

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Transformer Basic

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Distribution and

Basics about Magnetic Field

Magnetic field of force

Magnetic lines of force S N S N

Caution: This is a visualisation technique

Eddy currents and Hysteresis

Now we will replace the battery with A.C. generator...

For Long distances: High Voltage/Low Current ~ High Pressure/low flow

Suitable for Transmission, but not for Consumption

For Short distances

Suitable for Consumption and short distances

Generating electricity at High

To convert electrical energy from

Secondary 250V, 40A:

Major Transformer Parts

Made from Core steel

Source of magnetic field

No Load Loss (Fe)

Load Loss (Cu) No Load Losss

I2R Loss due to current flow

kVA same for both sides:

Conservator takes up the

No damage on any part of transformer

good paint pretreatment & finish

PROCESS DIRECT LABOUR PRODUCTION PROCESS OPERATING COSTS TOTAL

INDIRECT EXPENSE APPRAISAL COSTS

OH COSTS: PREVENTION COSTS AND EXTERNAL FAILURE COSTS

Number of CAR/PAR raised during 1997

Source - CAR/PAR log

1997 - Cost of Rework from Warranty claims only

Total Cost $44.122,-

1997 - Cost of Captured Rework

Warranty Cost $44.122,-

1997- Grouping by Cause of occurrence

This section important mainly for NLL performance of transformer

Correct conductor size and material

This section important mainly for NLL performance of transformer

This section important mainly for NLL performance of transformer

Correct Core/Coil packing

This section is important for every aspect of transformer performance

Signed by .......................................... Date: ...../...../.....

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