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- The document provides details about a field visit report to LTL Transformers (Pvt) Ltd, the leading transformer manufacturer in Sri Lanka.
- LTL was established in 1982 as a joint venture between the Ceylon Electricity Board and private investors. It now supplies over 2,000 transformers annually to Sri Lanka and exports 50% of its production.
- The factory uses modern manufacturing processes and materials like CRGO steel to produce transformers up to 33kV capacity. Windings are made of copper or aluminum and insulated with diamond dotted paper. Core laminations are cut using a GEORG cutting line.
Исходное описание:
Field visit report to transformer manufacturing company in sri lanka
- The document provides details about a field visit report to LTL Transformers (Pvt) Ltd, the leading transformer manufacturer in Sri Lanka.
- LTL was established in 1982 as a joint venture between the Ceylon Electricity Board and private investors. It now supplies over 2,000 transformers annually to Sri Lanka and exports 50% of its production.
- The factory uses modern manufacturing processes and materials like CRGO steel to produce transformers up to 33kV capacity. Windings are made of copper or aluminum and insulated with diamond dotted paper. Core laminations are cut using a GEORG cutting line.
- The document provides details about a field visit report to LTL Transformers (Pvt) Ltd, the leading transformer manufacturer in Sri Lanka.
- LTL was established in 1982 as a joint venture between the Ceylon Electricity Board and private investors. It now supplies over 2,000 transformers annually to Sri Lanka and exports 50% of its production.
- The factory uses modern manufacturing processes and materials like CRGO steel to produce transformers up to 33kV capacity. Windings are made of copper or aluminum and insulated with diamond dotted paper. Core laminations are cut using a GEORG cutting line.
Name : S.P.M Sudasinghe Index No. : 100523G Field : EE LTL TRANSFORMERS (PVT) LTD
LTL Holdings Ltd., better known in its old name, Lanka Transformers, is one of the very few examples of a private-public partnership that has gone right in this country. The Ceylon Electricity Board is the major shareholder of LTL which was established in 1982. The company was set up thirty years ago to manufacture an annual transformer demand of just 700 for CEB and has now expanded to supply more than 2000 transformers. LTL Holdings Ltd., has expanded to power generation sector and initially they owned Lakdhanavi Ltd and LTL Galvanizers. Mr.U.D Jayawardana became the General Manager/Chief Executive Officer of the Company in the year 1988 and continues to be so during the past more than twenty years. LTL transformers is the leading and only one transformer manufacturer in Sri Lanka whose factory is located at Angulana and Mrs. Rukshika Pathberiya is the factory manager. LTL has technically collaborated with ABB of Norway and they have improved their production level with highly international standards to fulfil the entire Sri Lankan requirements while exporting about 50% of its production. Some major buyers of LTL Transformers are Jordan, Kenya, Uganda, Botswana, Mauritius, Tanzania, Ethiopia, Australia etc. As a company they work their entire process with higher responsibility, because they want to fulfil their customer satisfaction to great extent and also it affects the economy of the country not only due to their 100% share in the local market but also LTL transformers is one of the very few companies that government involved which earn profits .
MISSION Delight the customers by providing Transformers & Switchgear panels on time with excellent quality. VISION A Great Global Company through Technology & People. PRODUCTION PROCESS
Figure 1: Manufacturing Process of a transformer Low Voltage Winding Assembling High Voltage Winding Assembling Core Cutting Assembling & Clamping Assemble Active Part & insert top core Connect windings and Provide Tapings Drying (Oven) Tanking Manufacturing the Tank Filling oil under Vacuum Seal the Tank Testing Installation
LTL transformers are produced to the designs of ABB Norway, a global electrical giant, through a technology transfer agreement. For some orders they are designed by LTL engineers and the main objectives of their designs are Improvement of efficiency by reducing on load and no load losses. Emphasis on lowering costs by economizing the use of materials and planning manufacturing processes that would optimize labour inputs. The complying designs are satisfactory with respect to dielectric strength, mechanical endurance, dynamic and thermal withstand of winding in event of short circuits. Use of materials economically in order to achieve lower cost, lower weight, and reduce size and better operation performance. Specified performance characteristics such as temperature rise, noise level, impedance etc. Strong mechanical design, final finish and appropriate accessories. Ability to withstand high impulsive voltage surges. Overload capacity. Elimination or reduction of stray losses, hot spots, electrical gradients, etc. by electrical and magnetic field analysis. Products are designed according to the requirements of customers and they have the ability to produce up to 33kV and capacity up to **** These products are designed to fully meet all the latest national and international standards, including IEC (International Electrotechnical Commission), BS (British Standards), ANSI (American National Standards Institute).
Production Process 1. Winding Copper is normally used for any winding due to its higher conductivity. Some transformer windings are wound with Aluminium. But due to its low conductivity large conductors are required for windings and it causes the transformer to be bulky. But Aluminium winding transformers cost is somewhat lower than Copper winding transformers even though higher losses of Aluminium are taken in to consideration. But due to the difficulties in installation, maintenance and transportation of Aluminium winding transformers, they are not much used. Aluminium is only used for windings if the customer request it.
1.1 Low Voltage Winding First step is to wound low voltage winding using Copper foils and DDP (Diamond Dotted Paper) as insulation material between turns. Copper foils are used due to the higher currents in LV side. Diamond dotted paper not only provide the insulation between turns but also it increase the strength of winding to withstand the magnetic force exerted on it.
Diamond Dotted Paper
Diamond Dotted Paper is made of Kraft paper coated with heat curable epoxy resin. The epoxy adhesive is applied to both sides of the paper in a diamond pattern consisting of 9.5mm x9.5mm diamonds with 15.9mm center spacing. The epoxy resin, which cures during the heating process, forms a high strength bond. This bond prevents the windings from moving during operation or under short circuit stresses. The diamond pattern epoxy resin treatment improves the temperature resistance and thermal performance of the kraft paper. The combination of high kraft paper strength and high epoxy resin bond strength gives the greater strength and coil integrity throughout the life of the transformer. It costs about 2$ per kilogram of DDP.
1.2 High Voltage Winding After completing the Low Voltage winding High voltage winding is wound on top of that. Insulation between LV and HV windings are accomplished by using oil. At this stage about 19 mm air gap is made on top of LV winding using spacers and HV winding is wound on top of that. Oil is filled to these spaces after filling oil to the tank which also acts as a cooling medium. After completing the HV winding, the gap between two windings will be about 16 mm. Wood is also used as spacer material.
Figure 2: Diamond Dotted Paper Figure 3: Spacer material
HV winding is wound with enamelled insulated round (or rectangular) conductors. Conductor diameter is decided depending on the required capacity (Power) of the transformer. Diamond dotted paper insulation is used between two HV layers.
Both of these two windings are wound as circular windings. The nature of the leakage flux is such that it is mostly in the axial direction (except in the ends of the windings) and hence the maximum radial force occurs around the mid-height of the coils. Radial forces act outward on the outer winding (HV winding) and inward on the inner winding (LV winding) (Fig 4a). In circular coils any radial forces tend to be distributed uniformly along the circumference of the coil. In circular windings the radial forces are resisted by the strength of the winding conductors, and in some cases the low-voltage winding tubes. Under radial forces the rectangular windings tend to become circular (Fig 4b,c). This results in substantial change in geometry and the impedance. There is also a vertical force (axial) exerted on windings and they are resisted by the stiffness of the radial spacers and the beam strength of the conductors.
All of these wounding processes are done by humans with the aid of winding machines. Each worker is specialized for their work and for the machine they use and it improves the productivity and also the quality of the output
(b) Circular winding remains circular (c) Rectangular winding tends to become circular (a)Forces on Windings Figure 4 Figure 5: Winding section of LTL transformers
Tapings are taken out from HV winding to minimize the current handling requirements of the contacts. Usually (for CEB orders) they provide 5 tap positions including nominal voltage, 2.5% of nominal voltage.
2. Core CRGO (Cold Rolled Grain Oriented) Steel is used as the core material. Size of CRGO Steel grains are about 2mm 5mm that is much larger than the size of regular steel where regular steel is about 0.5mm. This size difference helps to reduce hysteresis loss. Also the Chemical composition of CRGO steel has a higher percentage of silicon which in turn increases the resistance compared to regular steel which reduces eddy currents. Standard of LTL transformers is to maintain flux level 1.7 Wb/m 2 . Typically the core loss of their transformer is about 1W/kg of core material. Typical transformer consumes about 1000kg of CRGO steel to its core. Current market price of CRGO steel is about 2-3$/kg. Core laminations are cut from latest GEORG cutting line. There are some holes to provide cooling to the core.
Core laminations are cut and joint in step lap manner to reduce core loss further. For non-step lap core there is higher flux densities occurring at edges and it causes higher core loss. That effect is reduced in step lap core due to its flux path as shown in figure 7. This reduces the core loss about 15% for 15000 kVA transformer.
Figure 6: Core lamination (a) Flux path in non-step lap core (b) Flux paths in step lap core Figure 7
Core is designed so that the core efficiently fills the opening in the coil, leaving a minimum of unused space. They use different sizes of laminations as shown in figure 8 to increase the effective cross section of the core by using minimum amount of core material.
3. Assembling Active Part First the core structure is clamped with laminated wood or pre-fabricated steel clamps to prevent movement of the core structure so as to improve sound level characteristics and mechanical strength to withstand short circuit forces. Then the wound coils are inserted in to legs and press board insulations are used as phase barriers between the high voltage windings as well as between core and low voltage windings. Then the top core is fitted and clamped. Then phase windings are connected in star or delta manner internally. But in some designs all connections are brought out to externally connect the phase windings. Tapings brought out from HV winding are then connected to tap changer. Most usually there are 5 tapings per phase including nominal taping, 2 taping above and another 2 tapings below the nominal voltage. All the high voltage and low voltage winding leads are supported rigidly so that there will be no dangerous movements during severe faulty conditions and also to withstand mechanical vibrations. At this stage construction of active part of the transformer is finished, and it consists of the magnetic core, windings and other accessories such as tap selectors and bushings. Then they are stored until the drying process.
Figure 8: Method used to increase effective cross section of core Figure 9: Active parts ready to be drying
4. Drying Active part of the transformer is drying in transformer core oven. Drying is done at 120 0 C for about 20 hours. This drying is done for Curing of epoxy coated insulation and strengthen windings Remove moisture within the active part assembly After the drying is done the active part is tanked and oil filling is done within 30 40 minutes.
5. Tanking and Oil filling Transformer tank is usually manufactured at LTL Galvanizers, Sapugaskanda which is another steel fabrication company of LTL Holdings. Sometimes tanks are manufactured at Angulana factory itself. They use both sealed type and conservatory type tank designs to their transformers. The Sealed type Transformer tanks are made of high quality pre formed corrugated fin walls made out of cold rolled steel. Corrugated fin walls helps to cooling faster. Vertical bending machine helps to form the corrugated tanks only with one welded seam. It is ensured that finished tanks meet over pressure requirements & permanent deformation limits specified by international standards. All welds are tested, ensuring 100% leak proof seams and mechanical strength In conservator type design, the main tank is completely filled with oil with a smaller oil reservoir mounted above the tank. High quality steel sheets are used for tank fabrication. For cooling pre- fabricated detachable radiator panels are used.
After tanking the unit oil is filled in to the tank under vacuum. Vacuum chamber is used for this process. Oil in the transformer acts as insulation medium as well as cooling medium. After the oil filling is done the tank is sealed and the production process is finished with that. (a) Sealed tank transformer (b) Conservator tank transformer Figure 10
6. Testing Each transformer is subjected to some tests after the production process is completed. All of these tests are conducted according to the IEC (International Electromechanical Commission) standard IEC 60076. Routine Test Each transformer is subjected to the following tests in the lab Pressure test Insulation resistance test Voltage ratio test DC resistance test Oil dielectric strength test Separate source voltage withstand test Induce overvoltage withstand test No load test Full load test Vector group test
Type test These tests are done only on the request of the customer or as a part of a verification of new design. Impulse voltage withstand test Sound level measurement test Temperature rise test Three phase symmetrical short circuit test Three phase symmetrical short circuit test is done usually in India. Some other type tests also done in India according the requirement of the customer. Impulse voltage withstand test is performed at University of Peradeniya and other test are done within the factory. Sound level measurement test is very difficult and costly test because it can only be done at non-working day in the factory.
Testing procedure can be changed due to the requirements of customers. Sometimes LTL has to do all of these tests completely from outside the company if customer request to do so.If any transformer fails under any test then it should be reassembled or should try to fix the error. Reassembling the defected transformer is very difficult task and sometimes it is economical to construct new transformer to replace that defected one and some materials from defected transformer can reuse. LTL transformers provide transportation and installation facilities if it is requested by the customers. Also LTL transformers produce package substations for customer orders. Package substations are compact arrangement that simplifies conventional substation designs. It includes high voltage compartment, transformer compartment and low voltage compartment. They are designed according to IEC 62271-202 and customer specified other standards.
Cost Manufacturing of typical distribution transformer costs about 700,000 LKR including all material and labour costs. About 30% of the cost is for winding copper because market price of copper is about 6$/kg. Aluminium is cheaper than copper but it causes the transformer to be very bulky. Another major source of cost of the transformer is for core steel. It is about 10% of the total cost. CRGO steel price is about 3$/kg. Typical transformer needs about 1000kg of CRGO steel. Transformer oil is another major cost factor which contributes about 40% of the total cost of the transformer.
Resent Improvements in Production Process They use new winding technique for high voltage winding to reduce the amount of copper required for windings. Core laminations are cut from new machine GEORG cutting line.
Figure 11: Testing Department of LTL Transformers
CONCLUSIONS
As a Sri Lankan company I noticed many positive things in LTL transformers. Management of the company is totally independent from the government and all of the workers and the management has a goal for success of the company. LTL has the 100% share of the local market including CEB. But they also go beyond that and arrive to the global market and face to the huge competition in the global market well. 50% of their production is exported. The great thing is that they design their products according to the customer requirements and also the testing procedures also conducted according to customer requirements. It helps to increase the demand for their products. Most of the tests were done within the factory of LTL. But impulse voltage withstand test and three phase symmetrical short circuit test cannot be done within factory. It is better if they can improve the facilities to do these two tests within factory and it will reduce the testing cost for specially tests done at India. LTL has export their products to many countries such as Jordan, Kenya, Uganda, Botswana, Mauritius, Tanzania, Ethiopia and Australia. In month of June, 30 container loads of transformers will be shipped to Jordan and Ethiopia. Ethiopias state owned power utility EEPCO early this year signed up LTL for supply of two electrification projects funded by the World Bank and African Development Bank. These orders are for more than 1,800 transformers in less than six months of production time. This order alone accounts for sale of Rs. 1,100 million and sales to CEB now accounts for less than 50% of its turnover. It is better if they can enter to the European market also. LTL has technical collaboration with ABB Company. It is a good opportunity to share the technical knowledge with a giant company in the global industry. It is better to increase their own designs and experiments to increase the efficiency of their products. There should be compromise between efficiency and cost of the product. There are no more or no less amount of employees than the required amount. They can easily increase their production rate if they can find new market.