INDUSTRIAL TRAINING REPORT

TOPIC-GENERATING TRANSFORMER MANUFACTURING

BHEL BHOPAL

PRESENTED BY :- PRESENTED TO :-
PRAVEEN KUMAR SINGH DR. NAVNEET KUMAR
ROLL NO. (1673520034) ASSISTANT PROFESSOR
EE FINAL YEAR EE DEPARTMENT
REC BIJNOR REC BIJONR
GENERATING TRANSFORMER-
• The generator transformer is the largest transformer on a power station and connects the generator
output to the grid.
• The generator transformers, in most present day stations will have a voltage ratio of 23.5/400 kV.
• The important criteria which influence the generator transformer design are as follows:

• The HV volts are high — usually 400 kV.

• The LV current is high — almost 20 000 A for an 800 MVA transformer.
 STEPS IN MANUFACTURING OF GENERATING
TRANSFORMER-
 Design and drawing
 Core building
 Winding manufacturing
 Coil assembling
 Unlacing of core
 Core coil assembling and TG mounting
 Case fitting
 Process in plant
 Testing
 Preperation for dispatch
 M/C Tap changer
component
PICC/CTC
procurement Radiator/
Bushing
cooler
Coil
Mould
winding
component
Coil Core and coil Process in Case
assembling assembling and plant fitting Test lab
Insulating TG mounting
component
Core Building
Prepration
Mechanical Insulating
for dispatch
component component
Bottom
Top tank
CRGO tank

Insulating
component
Tank fabrication
and manufacturing
DESIGN AND DRAWING-
1-phase
 Phase

3-phase
KVA
 Rating

MVA
50 Hz
 Frequency

60 Hz
Generating
 Purpose
Substation
Distribution
TRANSFORMER CORE BUILDING:-

Following steps are involved in power transformer core construction:

 Material used-
CRGO(cold rolled grain oriented) silicon steel
 Laminated sheets of CRGO are made by slitting and cropping machine.
 Slitting machine decides width of lamination.
 Cropping machine decides shape and size of lamination.
 Stacking of CRGO
 End Frame insulation and Insulated Bolting of End Frame.
 Slitting and cutting
CRGO

End Frame insulation & End Frame bolted Stacking of CRGO

WINDING MANUFACTURING:-
TYPES OF WINDING MACHINES –
Winding Machines are of two types:
 Horizontal Winding machines
 Vertical Winding machines

Horizontal Winding machine Vertical Winding machine

TYPE OF WINDING IN TRANSFORMER:-

 Halical winding(mainly used for LV winding)

 Disc winding(mainly used for HV winding)

Disc winding
Halical winding
TYPES OF WINDING CONDUCTORS:-
The various types of conductors used in coil winding are-
 CTC (Continuously Transposed Conductor)
 PICC (Paper Insulated Copper Conductor)
 BPICC (Bunch Paper Insulated Copper Conductor)
COIL ASSEMBLY:-
The coils are specified in the design may be of following types on the basis of operating
voltage:-
 L.V. Coil Winding
 H.V. Coil Winding
 Tap Coil Winding
L.V. Coil is placed adjacent to the CRGO steel core and H.V coil outside, in order to
minimize the amount of insulation required.
While assembling the different coils (i.e. Tap coil, L.V. Coil & H.V. Coil) tap coil can be
placed in either of three positions depending upon the length of tap coil i.e. if tap coil is
small it is placed inside of LV coil, if it is medium then between LV & HV coil, and if large
then outside of HV coil.
Horizontal
Winding
(LV & Tap)

Vertical
Windin
g (HV)

Coil Assembly

Hydraulic Press Oven Baking

POWER ASSEMBLEY:-
Core - Coil Assembly
 Unlatching of core
 Fitting of bottom insulation
 Core coil assembly as per
drawing/electrical specification
Unlatching of core Core coil assembly as per
 Fitting of top insulation drawing

 Relacing of core

Relacing of core
Terminal Gear Mounting
 Crimping & Brazzing
 Insulation Wrapping
 OLTC Connection
 Vapour Phase Drying
 Servicing(due to porous in Terminal Gear Mounting
insulation)

Vapour Phase Drying of core & winding

CASE FITTING:-
Case Fitting involves connecting accessories of transformer,
these accessories include following :

 CT connections & Feed positions

 Conservator
 Bushing Connections
 Oil Temperature Indicator
 Buchholz Relay
1. Transformer tank 8. Drain valve
 Radiator
2. High voltage bushing 9. Breather
 Breather
3. Low voltage bushing 10. Oil temperature gauge
 Control panel(marshalling box)
4. Cooling radiator 11. Current transformer terminals
5. Cooling fans 12. Control panel
6. Conservator tank
7. System ground terminal
PROCESS IN PLANT:-

VPD(vapour phase drying) process is done after case fitting.

 To start VPD 7 mbar pressure is created.

 Solvant is heated to increase the pressure.
 Solvant started to flow to transformer under pressure.
 So dust and moisture is removed from transformer.
 Extra heating in transformer is provided transformer by steam.
 After that oil is poured in transformer.
 24 hrs sucking of oil by insulation.
 Oil is removed after that transformer goes for servicing.
 Again oil is filled for cooling and insulation and oil is tested(resistivity,breakdown voltage etc.)
TESTING OF TRANSFORMER:-
Routine tests-
I. Measurement of voltage ratio,polarity,magnetic balance and mag current.
II. Measurement of no load loss/core loss and no load current.
III. Seprate source voltage.
IV. Switching impulse voltage withstand test.
T- type tests
I. Temperature rise test
II. Zero sequence impedence test
III. Measurement of harmonics in no load current
IV. Measurement of sound level
 DISPATCH:-

 After successful completion of testing, transformer is handed over to dispatch sections. At this
stage after checking oil leakage, dismantling of all bushings, turrets etc. and covered with the
blanking plates and the tank is fitted with nitrogen gas and then the transformer is dispatched
to the concerned site.
THANK YOU