Maulana Azad National Institute

of Technology (MANIT)

Vocational Training Report

(Posted Department- TRM)
Submitted To
Submitted By
Dr. Mukesh Arora

Pranay

Vijayvargiya
AGM (IT)

B.Tech

(2nd Year)
MANIT,
BHOPAL

ACKNOWLEDGEMENT
I would like to thank my project co-coordinator Dr. Mukesh
Arora, for providing all the materials possible and encouraging
me throughout the course. It is a great pleasure to
acknowledge the assistance and contributions of all the
engineers of TRM department, BHEL BHOPAL for their prompt
and timely help in the official clearances and valuable
suggestions during the time of this training. I would also like to
express my profound gratitude to TRM DEPARTMENT for
constant and valuable suggestions while doing the training
work.

Pranay Vijayvargiya
B.Tech (2nd Year)
MANIT, BHOPAL

CERTIFICATE
This is to certify that Pranay Vijayvargiya, student of
B.Tech 2nd year from MANIT, Bhopal has completed his
Vocational Training at BHEL, Bhopal from 2nd May, 2013
to 12th June, 2013.

I have found him sincere, hardworking and technically

sound. He has worked well as part of a team during his
tenure. I take this opportunity to wish him well for the
future.

PROJECT GUIDE
Dr. Mukesh Arora
AGM (IT), BHEL BHOPAL

DECLARATION
I, J .Ravi Kiran declare this training report submitted by
me an original piece of work aimed towards the partial
fulfillment of my B.Tech (Electrical Engineering)
graduate program, under the guidance of Dr. Mukesh
Arora (DGM), TRM division BHEL, Bhopal.

Pranay Vijayvargiya
B.Tech (2nd Year)
MANIT, Bhopal

BHEL - AN INTRODUCTION
Bharat Heavy Electricals Limited is a name recognized
across the industrial world. BHEL ranks among top 12 leading
international companies in power field and it is largest
engineering and manufacturing enterprises of its kind in India.
Established in late 50s, the company provides products
systems and service in the field of power generation,
transmission and utilization. Non conventional energy sources,
industry, transportation, oil, gas exploration &
telecommunication. BHEL has 14 manufacturing divisions & 4
power sector regional centers & 18 regional offices & a large no
of project sites spread all over India & 45 countries. Its export
ranges from individual products to turnkey power plants &
consultancy services. All major manufacturing erection &
service unit of BHEL have been awarded ISO 9000
certification.
BHEL Bhopal plant is the oldest unit of company. The product
range al Bhopal includes hydro, steam , marine & gas nuclear
turbines, hydro & turbo generators, transformers,
transportation equipments , capacitors , bushings , electrical
motors , rectifiers , oil rig equipments , switch gear & control
gears.

MAJOR CUSTOMERS OF
B.H.E.L
Supplied to all major utilities in India :
National Thermal Power Corporation (NTPC)
PGCIL
NJPC
NHPC
NLC
NPCIL
NEEPCO
APTRANSCO
APGENCO
JPPCL
ALL State Electricity Boards (SEBs)
Abroad:
TNB, Malaysia
PPC, Greece
MEW, Oman
OCC, Oman
GECOL, Libya
Trinidad & Tobago

CONTENTS
S. No.
1.

NAME OF ASSEMBLY:INTRODUCTION

2.
3.

CORE AND PUNCH

INSULATION SHOP

4.

WINDINGS

5.

COIL ASSEMBLY

6.

POWER ASSEMBLY

7.

TECHNICAL DEVELOPEMENT

8.

INSTRUMENT

INTRODUCTION
A transformer is a device that transfers electrical energy from
one circuit to another through inductively coupled conductors
the transformer's coils A varying current in the first
or primary winding creates a varying magnetic flux in the
transformer's core and thus a varying magnetic field through
the secondary winding. This varying magnetic field induces a
varying electromotive force (EMF), or "voltage", in the
secondary winding. This effect is called mutual induction.
If a load is connected to the secondary, an electric current will
flow in the secondary winding and electrical energy will be
transferred from the primary circuit through the transformer to
the load. In an ideal transformer, the induced voltage in the
secondary winding (Vs) is in proportion to the primary voltage
(Vp), and is given by the ratio of the number of turns in the
secondary (Ns) to the number of turns in the primary (Np) as
follows:

By appropriate selection of the ratio of turns, a transformer

thus allows an alternating current (AC) voltage to be "stepped
up" by making Ns greater than Np, or "stepped down" by
making Ns less than Np.
In the vast majority of transformers, the windings are coils
wound around a ferromagnetic core, air-core transformers
being a notable exception.
Transformers range in size from a thumbnail-sized coupling
transformer hidden inside a stage microphone to huge units
weighing hundreds of tons used to interconnect portions
of power grids. All operate with the same basic principles,
although the range of designs is wide. While new technologies
have eliminated the need for transformers in some electronic
circuits, transformers are still found in nearly all electronic
devices designed for household ("mains") voltage. Transformers

are essential for high-voltage electric power transmission,

which makes long-distance transmission economically practical.

BASIC PRINCIPLE
The transformer is based on two principles: first, that
an electric current can produce a magnetic
field (electromagnetism), and, second that a changing
magnetic field within a coil of wire induces a voltage across the
ends of the coil (electromagnetic induction). Changing the
current in the primary coil changes the magnetic flux that is
developed. The changing magnetic flux induces a voltage in the
secondary coil.

An ideal transformer is shown in the adjacent figure. Current

passing through the primary coil creates a magnetic field. The
primary and secondary coils are wrapped around a core of very
high magnetic permeability, such as iron, so that most of the
magnetic flux passes through both the primary and secondary
coils.

ENERGY LOSSES
An ideal transformer would have no energy losses, and would
be 100% efficient. In practical transformers, energy is
dissipated in the windings, core, and surrounding structures.
Larger transformers are generally more efficient, and those

rated for electricity distribution usually perform better than

98%.
Experimental transformers using superconducting windings
achieve efficiencies of 99.85%. The increase in efficiency can
save considerable energy, and hence money, in a large heavily
loaded transformer; the trade-off is in the additional initial and
running cost of the superconducting design.
Losses in transformers (excluding associated circuitry) vary
with load current, and may be expressed as "no-load" or "fullload" loss. Winding resistance dominates load losses,
whereas hysteresis and eddy currents losses contribute to over
99% of the no-load loss. The no-load loss can be significant, so
that even an idle transformer constitutes a drain on the
electrical supply and a running cost. Designing transformers for
lower loss requires a larger core, good-quality silicon steel, or
even amorphous steel for the core and thicker wire, increasing
initial cost so that there is a trade-off between initial cost and
running cost (also see energy efficient transformer).
Transformer losses are divided into losses in the windings,
termed copper loss, and those in the magnetic circuit,
termed iron loss. Losses in the transformer arise from:

Winding Resistance
Current flowing through the windings causes resistive
heating of the conductors. At higher frequencies,skin
effect and proximity effect create additional winding resistance
and losses.
Hysteresis Losses

Each time the magnetic field is reversed, a small amount of

energy is lost due to hysteresis within the core. For a given core
material, the loss is proportional to the frequency, and is a
function of the peak flux density to which it is subjected.
Eddy Currents
Ferromagnetic materials are also good conductors and a core
made from such a material also constitutes a single shortcircuited turn throughout its entire length. Eddy
currents therefore circulate within the core in a plane normal to
the flux, and are responsible for resistive heating of the core
material. The eddy current loss is a complex function of the
square of supply frequency and inverse square of the material
thickness. Eddy current losses can be reduced by making the
core of a stack of plates electrically insulated from each other,
rather than a solid block; all transformers operating at low
frequencies use laminated or similar cores.

Magnetostriction
Magnetic flux in a ferromagnetic material, such as the core,
causes it to physically expand and contract slightly with each
cycle of the magnetic field, an effect known
as Magnetostriction. This produces the buzzing sound
commonly associated with transformers that can cause losses
due to frictional heating. This buzzing is particularly familiar
from low-frequency (50 Hz or 60 Hz) mains hum, and highfrequency (15,734 Hz (NTSC) or 15,625 Hz (PAL)) CRT noise.
Mechanical Losses
In addition to magnetostriction, the alternating magnetic field
causes fluctuating forces between the primary and secondary
windings. These incite vibrations within nearby metalwork,
adding to the buzzing noise and consuming a small amount of
power.

Stray Losses
Leakage inductance is by itself largely lossless, since energy
supplied to its magnetic fields is returned to the supply with the
next half-cycle. However, any leakage flux that intercepts
nearby conductive materials such as the transformer's support
structure will give rise to eddy currents and be converted to
heat. There are also radiative losses due to the oscillating
magnetic field but these are usually small.

CLASSIFICATION OF TRANSFORMERS
1. According to method of cooling
a. Self-aircooled (dry type)
b. Air-blastcooled (dry type)
c. Liquid-immersed, self-cooled
d. Oil-immersed, combination self-cooled and air-blast
e. Oil-immersed, water-cooled
f. Oil-immersed, forced-oilcooled
g. Oil-immersed, combination self-cooled and watercooled
2. According to insulation between windings
a. Windings insulated from each other
b. Autotransformers
3. According to number of phases
a. Single-phase
b. Polyphase
4. According to method of mounting
a. Pole and platform
b. Subway
c. Vault
d. Special
5. According to purpose

a. Constant-voltage
b. Variable-voltage
c. Current
d. Constant-current
6. According to service
a. Large power
b. Distribution
c. Small power
d. Sign lighting
e. Control and signaling

CORE
Laminated transformer core

The core of a laminated transformer consists of a stack of

punched sheet alloy made of iron and nickel (the laminations).
The percentage of nickel is adjusted to give a reduced energy
loss when the core is magnetized by the magnetic field
produced when the primary winding is energized. Further
improvements are made to the molecular structure by a rolling

process. The typical flux density 0.5mm thick material is 1.3 to

1.5 tesla. For grain orientated material a higher flux density is
used to minimize the size but incurs an increased cost. A
further process is carried out to insulate the surface of the
sheet by heat treatment, either gas or chemical. This is to
reduce eddy currents that would flow from lamination to
lamination. The punching process causes a slight degradation
in the performance and further heat treatment may be
required.
Generally three thicknesses of lamination are manufactured,
0.5mm and 0.35mm for 50Hz and up to 400Hz, 0.1mm up to
1000Hz. Higher frequencies can be used but the flux density
would have to be reduced to minimize core losses and reduce
distortion, for example in amplifier output transformers.
Note: Because of the gaps in the magnetic circuit and the
lamination material, the switch on in rush current is lower than
the equivalent power rated toroidal transformer. The size of a
laminated transformer is typically larger than the equivalent
power rated toroidal transformer.

Toroidal transformer core

A toroidal core is constructed using a strip of nickel iron
material wound in a helix to form a circular core.The typical
thickness suitable for most applications is 0.35mm however
0.1mm is more common for high frequency applications. The
process to manufacture the strip is similar to the material used
in the laminated transformers. Because no punching of the
material is required the it has an improved magnetic

performance although after the material is cut to width and

formed into a roll a further heat treatment is carried out. The
permeability of the wound core is greater than its equivalent
laminated transformer which has punching losses and gaps in
its magnetic circuit. Due to the improved core characteristics
toroids can be run at 1.6 to 1.8 tesla with low core losses and
low Imag currents. This improved core performance allows the
size of toroid to be smaller than the equivalent laminated
transformer.
Note: For large toroidal transformers the high permeability and
lower core losses may give rise to large inrush currents when
switched on. This can be reduced by methods of winding and
by reducing flux density or providing soft start circuitry. The
transformer may have to be run from class D MCBS (circuit
breakers).
Ferrite transformer core
The Ferro ceramic material used in the magnetic core can be
moulded and fired to give a wide number of core shapes and
styles. These include EE, EI, UI, ETD, EC, RM, PM toroid etc. The
maximum size is limited but multiples of EE, EI & UI can be
used to make larger sizes. The frequency range has increased
over time due to the research into new materials by the core
manufacturers and can be used in power circuits up to 5MHz &
beyond. For some of the more exotic materials the flux density
has to be reduced to minimise core losses.By changing the
material used, i.e. iron powder and other mixtures the
characteristics of the core can be changed to give a wide range
of permeability values with high DC bias ability in both EI style
and toroidial form.
CRGO Imported from:
1) Nippon Steel Corporation, Yawata Works (Japan)
2) VIZ-Stal Ltd., Etakerinburg (Russia)
3) POSCO

INSULATION SHOP
The service life of a distribution transformer is governed by the
condition of the insulating material. Deterioration of the
transformer insulating material reduces the dielectric strength
and also reduces the ability of the transformer to withstand
short-circuit
events.
Korea's
domestic
transformer
manufacturers use varnish to improve winding mechanical
strength. However, the solidified varnish deteriorates over time,
which adversely affects the characteristics of the transformers.
By improving insulation performance and the short-circuit
withstand strength of distribution transformers, the cost of
maintaining and replacing these transformers can be reduced.
Many pole-type transformer failures could be avoided by using
a hybrid insulation, where layers of aramid papers and cellulose
papers are used. Additional design modifications include
reducing the number of cooling ducts between layers and
reinforcing the frame of the transformer to improve short-circuit
withstand strength. Then, varnish impregnating process is not
required when this hybrid insulation is used. The higher
reliability and longer life anticipated of hybrid-insulation
manufactured transformers should result in cost savings to the
utility. Construction of oil-filled transformers requires that the
insulation covering the windings be thoroughly dried before the
oil is introduced. There are several different methods of drying.
Common for all is that they are carried out in vacuum
environment. The vacuum makes it difficult to transfer energy
(heat) to the insulation. For this there are several different
methods. The traditional drying is done by circulating hot air
over the active part and cycle this with periods of vacuum (hotair vacuum drying, HAV). More common for larger transformers
is to use evaporated solvent which condenses on the colder
active part. The benefit is that the entire process can be carried
out at lower pressure and without influence of added oxygen.
This process is commonly called vapour-phase drying (VPD). For

distribution transformers, which are smaller and have a smaller

insulation weight, resistance heating can be used. This is a
method where current is injected in the windings to heat the
insulation. The benefit is that the heating can be controlled
very well and it is energy efficient. The method is called lowfrequency heating (LFH) since the current is injected at a much
lower frequency than the nominal of the grid, which is normally
50 or 60 Hz. A lower frequency reduces the effect of the
inductance in the transformer, so the voltage needed to induce
the current can be reduce

Process of VPD
Basic Equipment of Vapor Phase Drying (VPD) plant:
a. Evaporator system.
b. Condensation system.
c. Autoclave.
d. Vacuum system.
e. Solvent Pumping system.
f. Heating system for evaporator and autoclave.
g. Heat recovery system.
h. Distillation equipment.
i. Special water extraction measuring equipment.
j. Computer aided process.
The whole process is carried out in % stages, which is as
explained below:
R1: Preparation:
In this first stage, the oven is prepared for the process. The job
is let inside the chamber by means of crane. All the instruments
and devices are checked for correct operation. The oil filling
pipe is placed in position. Thermocouple is attached to the core
of the transformer for temperature monitoring; drain plug is
connected by steel pipe, etc... Finally, the door is closed and
clamped by hydraulic pump.
H1: Heating Up:
The heating process is started after initial preparation. Pressure
of 7mBar is maintained within the autoclave. The capacity of
solvent tank is 12,000 L and a minimum of 5,000-6,000L is
maintained during the process. The heating cycle is of 48-60

Hrs and 2-3 intermediate pressure lowering (IPL) of 1.5-2 Hrs is

applied in between.
The job temperature is maintained between 105oC 125oC.
P1: Fine Pressure Reduction:
V1: Fine Vacuum:
When water is obtained at 50mL/hour is obtained for three
hours in three simultaneous reading at 105oC 125oC
temperature and 0.2 Torr pressure, the solvent is closed down
through valves.
The job is flooded with oil and it is soaked for a minimum of
12Hrs.
A1: Aeration:
The vacuum inside the clave is broken down and air is let
inside. Oil is drained from the job and it is sent to the assembly
unit for servicing.
Post servicing, the job is let in for P2 process. This is generally
carried out by conventional process only. The ob is heated to
100 +/- 5oC 0.2 torr vacuum pressure. When simultaneous 3
reading of 50mL/hour of water is obtained for 3 hours, the job is
sent to Testing department for further process in oil-filled
condition.
Transformer Oil Properties
- High insulating
- Low Viscosity
- Low Surface Tension
- Optimum Cooling Point
- Low Decomposition
Advantages of VPD:
01. Fast, uniform heating up of the material to be dried.
02. Substantial reduction in the drying cycle of the transformer
compared to conventional process.
Sr.
Convention VPD
al Process
Process
1st Process 12 to 15
5 days
days
2nd Process 07 to 08
3 days
days
03. Little de-polymerization of insulating material.
04. Optimum and homogeneous drying quality, since the
heating process takes place in practically air free atmosphere,
i.e. NO2.

WINDINGS
The conducting material used for the windings depends upon
the application, but in all cases the individual turns must be
electrically insulated from each other to ensure that the current
travels throughout every turn. For small power and signal
transformers, in which currents are low and the potential
difference between adjacent turns is small, the coils are often
wound from enameled magnet wire, such as Formvar wire.
Larger power transformers operating at high voltages may be
wound with copper rectangular strip conductors insulated by
oil-impregnated paper and blocks of pressboard.
Highfrequency transformers operating in the tens to hundreds of
kilohertz often have windings made of braided Litz wire to
minimize the skin-effect and proximity effect losses. Large
power transformers use multiple-stranded conductors as well,
since even at low power frequencies non-uniform distribution of
current would otherwise exist in high-current windings. [62] Each
strand is individually insulated, and the strands are arranged so
that at certain points in the winding, or throughout the whole
winding, each portion occupies different relative positions in the
complete conductor. The transposition equalizes the current
flowing in each strand of the conductor, and reduces eddy
current losses in the winding itself. The stranded conductor is
also more flexible than a solid conductor of similar size, aiding
manufacture. For signal transformers, the windings may be
arranged in a way to minimize leakage inductance and stray
capacitance to improve high-frequency response. This can be
done by splitting up each coil into sections, and those sections
placed in layers between the sections of the other winding. This
is known as a stacked type or interleaved winding.Both the
primary and secondary windings on power transformers may
have external connections, called taps, to intermediate points
on the winding to allow selection of the voltage ratio.
In distribution transformers the taps may be connected to an
automatic on-load tap changer for voltage regulation of

distribution circuits. Audio-frequency transformers, used for the

distribution of audio to public address loudspeakers, have taps
to allow adjustment of impedance to each speaker. A centertapped transformer is often used in the output stage of an
audio
poweramplifier in
a push-pull
circuit.
Modulation
transformers in AM transmitters are very similar.

Certain transformers have the windings protected by epoxy

resin. By impregnating the transformer with epoxy under
a vacuum, one can replace air spaces within the windings with
epoxy, thus sealing the windings and helping to prevent the
possible formation of corona and absorption of dirt or water.
This produces transformers more suited to damp or dirty
environments, but at increased manufacturing cost.
TYPES OF WINDING

Reverse section winding

Helical winding
Spiral winding
Interleaved winding
Half section winding
The type of winding depends upon the job requirement.
Also, the width and thickness of conductors designed and
decided by design department.

COIL ASSEMBLY
Winding design and manufacturing practices for power and
distribution transformers has focused in the differences
between rectangular core and coils and layer windings common
in the production of distribution transformers and disc and
helical windings and circular core designs common in power
transformers. In the small power transformer market defined as
5-15 MVA, ONAN, with primary winding voltages up through 69
kV class, both core and coil designs arecommercially available.
Rectangular core and coils and layer windings offer the
advantage of lower costs for manufacturing compared to power
class circular core and coils with disc and helical windings.
Distribution transformers are applied at lower voltages, ratings
stated in KVA, lower short circuit and thermal duties serving
residential and commercial loads. Power transformers are
applied atvoltages from 15 kV to 765 kV and higher, ratings
stated in MVA, short circuit duties are high, thermal loading
variable and in some cases severe. Generator Step-up
transformers, unit auxiliary transformers, multiple winding
transformers, autotransformers, transmission and distribution
bulk power substation service with and without load tap
changing all must be designed to withstand the rigorous duty
for these power class transformer applications.

Circular core and coil winding construction with layer windings

can provide improvement for winding cooling, but usually does
not provide complete circulation of the oil to every conductor
and every layer of the windings. Even circular layer windings
still have significant quantities of winding insulation and
thought the space factor in the core and coils are an
improvement compared to the rectangular core and soil design,
it is not as good as a disc and helical circular core and coil
construction. The windings were constructed of rectangular
magnet wire with radial cooling spacers inserted between
multiples of layers. Reviewing the pictures above, vertical ribs
have been used to support the winding conductor and allow
vertical flow of oil for winding cooling; it appears that about
60% of the conductors might be in contact with the circulating
oil. However, there is no radial spacer allowing oil to contact
the conductor between turns. The end rings of the core and coil
assembly also include pressboard ribs allowing oil to flow into
the coil assembly and exit at the top for winding cooling.
Coil windings is of two Types:The precise details of the
winding arrangements will be varied according to the rating of
the transformers. The general principles remain the same
throughout most the range of transformer. The copper or
Alluminium strips/wires used in winding are meticulously
selected for its quality to give the best output.
1. Low Voltage (L.V) Winding
2. High Voltage (H.V) Winding
1. L. V. COIL WINDING: The Low Voltage coil is designed to
approximately match the current rating of the available lowvoltage (LV). The L.V. coil is normally wound on robust tube of

insulation material and this is almost invariably of synthetic

resin-bonded paper. This material has high mechanical strength
and is capable of withstanding the high loading. Electrically it
will probably have sufficient dielectric strength to withstand the
relatively modest test voltage applied to the L.V. winding during
the repairing without any additional insulation.
2. H. V. COIL COIL WINDING: The second process is H.V. Coil
Winding, which are wound with strip conductor and it usually
consists of continuous disc type. The coils are usually created in
layers and ideally all the joints are extremely well brazen and
insulated in order to withstand difficult service conditions and
tests.
The LV windings are made from Paper covered Copper Strip and
placed nearest to the core. The HV winding are wound with
Super Enameled Copper Wire or Aluminum wire or Paper
covered Round wire or paper covered Strip depending upon the
rating of the transformers. The cross section of the conductor is
also chosen to keep the thermal gradient in the winding to a
minimum and thus increase the life of transformer.
The coils are assembled with the best insulating material avail
and they are adequately clamped by the use of perm wood
rings where necessary to give required mechanical strength.
The tappings are provided o the external HV windings. The off
circuit tapping switch is gang operated type and good contact
is maintained by means of floating spring pressure. The tapping
switch can be looked in ay desired position. The transformer
preferably off capacity 2000 KVA and above can be supplied
with on load tap changer along with the desired controls as per
the requirement.
CORE AND COIL ASSEMBLY
A part of the transformer manufacturing process, the core and
coil assembly aspect plays a significant role where the core
assembly is vertically placed where the foot plate touches the

ground and the top yoke is removed. The limbs of the core are
tightly wrapped with cotton tape and then varnished during the
manufacturing and even repairing process.
First, the individual windings are assembled one over the
other to form the entire phase assembly.
The radial gaps between the windings are subdivided by
means of solid transformer board barriers.
Stress rings and angle rings are placed on top and bottom of
the windings to achieve a contoured end insulation design
for optimal control of the oil gaps and creepage stresses.
The complete phase assemblies are then carefully lowered
over the separate core legs and solidly packed towards the
core to assure optimal short circuit capability.
The top core yoke is then repacked and the complete core
and coil assembly is clamped.
The lead exits (if applicable) and the lead supports and
beams are installed. All winding connections and tap lead
connections to the tap changer(s) are made before drying
the complete core and coil assembly in the vapor phase
oven.
PROCESSING OF CORE AND COIL ASSEMBLY
The completed core and coil assembly is thoroughly dried to
pre-determined power factor readings by the vapor phase
drying process , providing the fastest, most efficient and most
effective drying of the transformer insulation available. The
vapor phase process uses the standard kerosene cycle method.
In this system, kerosene is vaporized and drawn by vacuum
into a heated autoclave where the transformer has been
placed. Condensation of the vapor on the core and coil
assembly rapidly causes the temperature to rise and allows
moisture to be drawn out of the insulation by the vacuum. High
temperature and pressure are used to accelerate the drying
process.
When the power factor measurements and the removal rate of
moisture have reached the required levels, the flow of kerosene
vapor is stopped and a high vacuum is used to boil off the
remaining moisture and kerosene. Because so much water is

removed in this process, the insulation physically shrinks in

size. Following removal from the autoclave, the transformer is
repacked as required and then undergoes its final hydraulic
clamping to ensure maximum short-circuit strength in the
finished product.
TAP CHANGING
Power Systems transformers can be equipped with either a deenergised tap changer or a load tap changer or with
both.Should load tap changing be required, BHEL can provide a
resistive bridging type or reactor type LTC. Both types offer up
to 500,000 operations between contact replacement and
substantially reduce maintenance intervals.The LTC can be
installed in the transformer tank with the diverter switch in its
own oil compartment, so that no contamination of the
transformer oil occurs due to arcing during switching, or can be
mounted on the main tank.
To prevent voltage surges on the tap changer during switching
MOV surge suppressors can be installed.

DRYING OUT PROCESS

In order to ensure power supply is completely reliable it
depends on high performance transformers and in order to
achieve that the drying out process is extremely important.
Under this process, the paper insulation and pressboard
material, which make up a significant proportion by volume of
transformer winding, have the capacity to absorb large
amounts of moisture from atmosphere. The presence of this
moisture brings about the reduction in the dielectric strength of
the material and also an increase in its noise.

TANK FABRICATION AND FITTINGS

The tanks are made of high quality steel and can withstand
vacuum and pressure test as specified in IS as well as by the
customers. All welds are checked ensuring 100 % leak proof

seems and mechanical strength. All tanks are pressure tested

before tanking the active part.
The Pressed steel radiators are used to dissipate heat
generated at rated load. The fin height and length are
calculated according to the rating of transformers as well as
customers' specifications. The fins can be plain or embossed.
The radiators are fitted variably according to the rating of
transformer. For smaller rating radiators are directed welded to
the main tank while for higher rating detachable type radiators
are provided with valves to facilitate during transportation and
handling at site.

The tanks are fabricated from MS plates. They are tested at a

pressure of 0.35 Kg/Sq. cm. for oil leakage output and they are
normally welded directly to the tank. However, transformers
can be supplied with detachable radiators.

TANKING
After vacuum drying process the active part is removed from
the Oven and all components subject to the shrinkage are
tightened again. The core & coil assembly is then placed into
the tank and properly lacked up during the transformer
manufacturing process. The temperature and exposure time is
monitored during this time to ensure that the transformer is not
too cool by the time it is get off from the oven. While in higher
rating transformer, the vacuum is drawn for a period of time
dependent on the voltage of the unit and time for which the
active part was exposed to the atmosphere and the humidity at
the time. The vacuum period is between 12 to 35 hours.
Meanwhile the external wiring and termination work to be
completed as per customer requirements.
PAINTING

The outside surface of tank including all fittings and accessories

are cleaned properly. Necessary chipping and grinding applied
for smooth surface and finishing. After cleaning of the tank, one
coat of hoi oil resistance pint is applied on the internal surface
of the tank during the transformer manufacturing process. The
outside surface is painted with one coat of Red Oxide Primer
and subsequently one coat of enamel paint as per customer's
requirement.

The transformers are fitted with Bare Porcelain Bushings and

metal parts conforming to IS specification 3347 "Dimension for
Procelain transformer Bushings." The electricals characteristics
of the bushings conform to IS 2099 "Specification for High
Voltage Porcelain Bushings". Alternatively transformers are
supplied, fitted with Cable Box either with Wiping type of glands
suitable for PVC/XLP cables.

TECHNICAL DEVELOPMENT
Loading capability of power transformers is limited mainly by
winding temperature. As part of acceptance tests on new units,
the temperature rise test is intended to demonstrate that at full
load and rated ambient temperature, the average winding
temperature will not exceed the limits set by industry
standards. However the temperature of the winding is not
uniform and the real limiting factor is actually the hottest
section of the winding commonly called winding hot spot. This
hot spot area is located somewhere toward the top of the
transformer, and not accessible for direct measurement with
usual methods. The temperature of solid insulation is the main
factor of transformer aging. With temperature and time, the
cellulose insulation undergoes a depolymerization process. As
the cellulose chain gets shorter the mechanical properties of
paper such as tensile strength and elasticity degrades.
Eventually the paper become brittle and is not capable
of withstanding short circuit forces and even normal vibrations
that are part of
Transformer life. This situation characterizes the end of life of
the solid insulation. Since it is not reversible, it also defines the
transformer end of life
This process is well known to transformer owners and sustained
efforts have been made to monitor the hot spot temperature to
take advantage of cool ambient
Temperature, extend the transformer life while providing
emergency overloading capabilities and taking advantage of
market opportunities. Figure 1 shows the sensitivity of paper to
temperature. Modern transformers make use of thermally
upgraded paper that has been chemically treated to improve
the stability of cellulose structure. The rated hot spot
temperature for this kind of paper is 110C and it can be seen
that an increase 7C will double the aging acceleration factor.
For older transformer build with normal Kraft paper, the rated
hot spot temperature is either 95C according to IEEE or
97Caccording to IEC. This paper is also very sensitive to
temperature and in case of emergency (assuming a hot spot
temperature of 140C) the aging acceleration factor is about
100, which means one hour in this condition is equivalent to
100 hours at the rated temperature.
Wet transformers (solid insulation showing more than 2% water
content) incur an

additional risk when operating at high temperature. It has been

shown that the residual water trapped in paper may reach
bubbling conditions and escape from paper under the form of
water vapor bubbles. These bubbles may move with the oil
flow, or get trapped in the winding and in both cases create a
threat for insulation breakdown. No wonder that the
transformer operator attempts to control the winding hot spot
temperature with the best mean available.

BUSHINGS

A bushing is a hollow electrical insulator through which a

conductor may pass. Bushings are used where high voltage
lines must pass through a wall or other surface,

on switchgear, transformers, circuit breakers and other high

voltage equipment.
DESCRIPTION
The bushing is a hollow insulating liner that fits through a hole
in a wall or metal case, allowing a conductor to pass along its
centre and connect at both ends to other equipment. The
purpose of the bushing is to keep the conductor insulated from
the surface it is passing through. Bushings are often made of
wet-process fired porcelain, and may be coated with a semiconducting glaze to assist in equalizing the electrical stress
along the length of the bushing.
The inside of the bushing may contain paper insulation and the
bushing is often filled with oil to provide additional insulation.
Bushings for medium-voltage and low-voltage apparatus may
be made of resins reinforced with paper. The use
of polymer bushings for high voltage applications is becoming
more common. The largest high-voltage bushings made are
usually associated with high-voltage direct-current converters.
Capacitor types
Some of the higher voltage types (layers of conductive paper,
film, ink or aluminum foil are used with an insulating medium)
are called capacitor bushings because they form a low value
capacitor between the conductor and the wall. This is done to
disperse the electrical field stress and thus reduce the peak
stress that could cause breakdown.

BUSHING FAILURE
Bushings sometimes fail due to partial discharge degradation in
the insulation. There is at present great interest in the
electricity supply industry in monitoring the condition of high
voltage bushings.

TESTING

The testing room is climatically controlled and is fully equipped

with facilities for conducting all routine tests and temperaturerise tests. The transformers are tested at various stages of
manufacture and various rating transformers are tested at
independent institution to establish short circuit and insulating
capacity of the transformers and also the impluse withstanding
withstanding capacity.
Prior to shipment, all transformers manufactured BHEL are
tested in accordance with the latest applicable standards
according to customer specifications. All industry standard and
optional tests with the exception of short-circuit tests, can be
performed in-house by trained personnel using accurate and
modern test equipment.

 Impulse Testing
A state-of-the-art digital impulse recording system, the Haefely
HIAS system, provides the most accurate analysis of impulse
results available today. Electronic recording of the impulse
current and voltage waveforms allows quick mathematical
comparisons to be made, including the difference between the
two waveforms under scrutiny. Accurate printed and plotted
final results are quickly available. If required, photographic
transparencies from the impulse oscilloscope can be supplied.
The construction of the test area incorporates a complete
copper mesh ground mat system, with extensive grounding
points provided. This eliminates high impedance grounds and
provides exceptionally clean test records. The impulse
generator is rated at 200 kV per stage for a total of 2.8 MV,
with 210 kJ total stored energy. For precise triggering, this
generator is equipped with a pressurized polytrigatron gap in
each stage. For chopped wave tests, a Haefely multiple
chopping gap is used. Our plants are fully capable of
performing lightning impulse, switching impulse and front-ofwave tests as required.
Induced Testing
For induced testing, a variable voltage alternator, rated
1500/1000 kVA, 3/1-phase, 170/240 Hz, is used. Voltage control
is by solid state automatic voltage regulator, and solid state
speed control of the 1000 kW DC driving motor. During the
induced test, partial discharge measurements both in pC and
V are taken and equipment is available to locate internal
partial discharges by the triangulation method.
Loss Measurement
Power is provided to the loss measuring system by a 5/10 MVA
regulating transformer feeding three single-phase 10 MVA
variable ratio transformers and a 110 MVAR capacitor bank.
Losses are measured by an automated system using CTs for
current and gas capacitors for voltage. This system has a fully
automated digital readout and printer.

 AC Testing
A test supply with an output voltage infinitely adjustable from
3-350 kV is available for high voltage AC testing. To measure
the applied voltage level, a digital peak-responding RMS
calibrated voltmeter capable of measuring up to 1600 kV is
used.
Short-circuit testing