CONTEXT

Abstracti List of figures...ii List of tables.iii

1.HISTORY1 2.INTRODUCTION2
2.1. How electricity is transported 2.2. Basic Principle

3.TransformerConstruction.7
3.1. Core Type Transformer 3.2. Shell Type Transformer

4.TRANSFORMERCORE.12
4.1. IMPORTANT ELECTRICAL PROPERTIES OF CRGO 4.2. CRGO steel processing 4.3. Core building 4.4. Selection of the Core Diameter

5. Winding Wires and Strips.21

5.1. Basic material and their processing 5.2. Paper covering on the conductors 5.3. Insulation paper 5.4. Choice of using chopper or aluminium as winding material 5.5. Selection of winding wires and strips 5.6. Selection of number of turns 5.7. Calculations of size of a high-voltage conductor 5.8. Calculation of size of a low-voltage conductor 5.7. Transposition 5.7. Insulation design

6. Transformer oil..30
6.1. Transformer Oil Testing

7. Various type of cooling..32

7.1. ONAN type cooling 7.2. ONAF type cooling 7.3. OFAF type cooling 7.4. Radiators
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8.Protecting Devices34
8.1. Bushings 8.2. Surge Arresters 8.3. Buchholz Relay 8.4. Breather

9. Step-by-step Manufacturing Process of Oil-Cooled Transformer..............40

9.1. Coil Winding 9.2. Core Assembly 9.3. Core-Coil Assembly 9.4. Tank-Up 9.5. Transformer Tanks 9.6. Testing Process 9.7. Finishing & Dispatch

CASE-STUDY..47

DECLARTION

I hereby declare that this project entitled MANUFACTURING PROCESS OF DISTRIBUTION TRANFORMERS represent the original work carried out by me during my mini project in department of Electrical and Electronics Engineering from TRR College of Engineering under supervision of Internal Guide towards the partial fulfillment of Bachelor of Technology Degree Electrical and Electronics Engineering from JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY. The work has not been for any degree or examination in any other university. All the assistance taken during the course of this project and source of literature has been duly acknowledged.

ABSTRACT
It is a mini project, which involves the study of Manufacturing Process of Distribution Transformer Absorbers. The object of this project is to study the Manufacturing process of Distribution Transformer step by step. Absorbers core construction and assembly, coil construction, core coil assembly, de-moistening technique, tanking and testing of distribution transformer. And also deals with the working principle of transformer. Materials used during manufacturing process. A transformer is essentially consist of magnetic core, build-up of insulated silicon steel laminations, upon which are wound set of coils suitably located with respected to each other and termed has primary and secondary windings. Such a combination may be used to derive a voltage higher or lower than what is immediately available. In the former case, the transformer is termed as step-up transformer, while in the latter case, its known has step-down transformer. Fast expanding industrialization of the country needs fast movement of higher safety of men and material. The study of the Manufacturing process of Distribution Transformer is essentially as it enhances our chances of improving its efficiency and quickly solves the problems of its failures. Hence, study of manufacturing process of Distribution Transformer absorbers gives us an approximate idea of its life time, the time for its servicing, causes of its failures.

Abbreviations

1.

ASTM 2. AC 3. BS 4. CRGO 5. DC 6. DVB 7. EGIP 8. EMF 9. ERW 10 HI-B . 11 HPSEB . 12 HV . 13 IS . 14 ISI . 15 ISO . 16 ISS . 17 LV . 18 PCB . 19 RMS . 20 UPPCL . 21 27 M4 . 22 ZDMH . 23. 24 A . 25 ASTM . 26 AC . 27 BS . 28 CRGO . 29 DC . 30 DVB .

American Standard for Transformer Alternate Current British Standard Cold Rolled Grain Oriented Direct Current Delhi Vidyut Board Electrical Grade Insulation Paper Electro Motive Force Electric Resistance Welding High Saturation Flux (Brand Name of CRGO) Himachal Pradesh State Electricity Board High Voltage Indian Standard Indian Standard Institute International Organization for Standardization Indian Standard Specification Low Voltage Chlorinated Bi Phenyl Root Mean Square Uttar Pradesh Power Corporation Limited Grade of CRGO Steel-M4, Thickness 0.27 mm Grade of CRGO Steel-ZDMH, Thickness 0.23 mm Diameter, Flux Ampere Volt Watt Ohm Kilo gram Millimetre Centimetre
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List of Figures

S.No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 2. 13. 4.

5. 6.

FIGURE Fig: (2.1) Fig: (3.1) Fig: (3.2) Fig: (3.3) Fig: (3.4) Fig: (3.5) Fig: (3.9) Fig: (4.1) Fig: (5.2) Fig: (5.1) Fig: (5.2) Fig: (5.3) Fig: (5.4) Fig: (5.5)
Fig: (7.1) Fig: (7.2)

NAME Step-down transformer showing magnetic flux Core-type Transformer Shell type transformer Core type Shell type Single phase Transformer Cross section of a 3-phase Distribution Transformer Rectangular cut lamination Miter-cut lamination Wires & strips Paper covered conductors Insulating paper Rectangle strip of low-voltage winding Transposition Stamped-plate radiators Tubular radiators Bushing Buchholz relay Breather Tanking Tank Painting Final assembly Transformer after Assembly

PG.No 5 7 8 9 9 10 11 17 17 21 22 23 26 28 33 33 34 38 39 42 43 43 45 45

7. 8. 9. 20. 21. 22. 23. 24.

Fig: (8.1) Fig: (9.1) Fig: (10.1) Fig: (11.1) Fig: (11.2) Fig: (11.3) Fig: (11.4) Fig: (11.4)

List of Tables
S.No 1. 2. 3. 4. 5. 6. 7. TABLE Table-1 Table-2 Table-3 Table-4 Table-5 Table-6 Table-7 NAME Important electrical properties of CRGO Important physical properties of CRGO Dimensions & Tolerances Tolerances in Dimensions & Shape - conform to JIS C 2553 Hi - B CRGO Materials Core losses Comparison of space factor of round and rectangle conductors PG.No 13 14 14 15 16 16 25

8.

Table-8

Comparison of a single thick strip with multiple strips in parallel. In respect of surface length

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Company Profile
Vishwanath Transformers Limited was incorporated in the year 2004 as Engineering, Design and Manufacturing Company for Power and distribution transformers. The Company is accredited with ISO 90012008 certificate from TUV India Ltd for its Quality systems and Procedures, and also accredited with BEE (Bureau of Energy Efficiency) star rating for transformers.

The Certification of ISO 9001:2008 ensures that establishment procedures are followed in all areas of operation such as Design, Marketing, Planning, Purchase, Production, Inspection at all stages till Dispatch. Since our establishment in 2004, at Hyderabad, we have been dedicated to the design, development and manufacturing of a wide range of transformers. Our extensive variety of Transformers include Distribution and Power Transformers as per the customer specifications,
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with Six years of dedication and exertion, Vishwanath Transformers Ltd has introduced a number of pioneer electrical equipments, became sole agent, distributor and joint-venture business partner of suppliers. -----Vishwanath Transformers Limited is well known for its excellent quality products along with high level of commitment to its customers.

ACKNOWLEDGEMENT
Taking up the execution of project work a rich experience by itself as it involved more of my efforts. It was the first opportunity for me to apply my knowledge and Skill to work up on an idea which certainly will be after stepping into the field work. My sincere thanks to external project guide S.V. SUBBA REDDY, Manager (Tech) Vishwanath Transformers Limited, for the guidance and pertaining to use lab facilities and carry out this project work. I express my profound gratitude to our guide Prof.Mr.SRIDHER Of EEE department for his support and encouragement in completing the project. I thank him for his project guidance and help through the development of this project by providing me with required information. Without his guidance cooperation and encouragement, I couldnt have learned many things during my project venture I would like to thank Prof.V.H.N.SHARMA, Head of the department of ELECTRICAL & ELECTRONICS ENGINEERING for his valuable guidance in bringing shape to this dissertation.
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I express my special thanks to principal Dr.K.SRINIVAS on of our EEE department for his kind co-operation.

P.KIRAN (08L01A0245)

B.Srinivas (08L01A0207)

E.Nirenjen Kumar (08L01A0215)

History
Michael Faraday built the first transformer in 1831, although he used it only to demonstrate the principle of electromagnetic induction and did not foresee its practical uses. Russian engineer Pavel Yablochkov in 1876 invented a lighting system based on a set of induction coils, where primary windings were connected to a source of alternating current and secondary windings could be connected to several "electric candles". The patent claimed the system could "provide separate supply to several lighting fixtures with different luminous intensities from a single source of electric power." Evidently, the induction coil in this system operated as a transformer. Lucien Gaulard and John Dixon Gibbs, who first exhibited a device with an open iron core called a 'secondary generator' in London in 1882 and then sold the idea to American company Westinghouse. This may have been the first practical power transformer. They also exhibited the invention in Turin in 1884, where it was adopted for an electric lighting system William Stanley, an engineer for Westinghouse, built the first commercial device in 1885 after George Westinghouse had bought Gaulard and Gibbs' patents. The core was made from interlocking E-shaped iron plates. This design was first used commercially in 1886. Hungarian engineers Zipernowsky, Blthy and Dri from the Ganz Company in Budapest created the efficient "ZBD" closed-core model in 1885 based on the design by Gaulard and Gibbs. Their patent application made the first use of the word "transformer". Russian engineer Mikhail Dolivo11

Dobrovolsky developed the first three-phase transformer in 1889. In 1891 Nikolas Tesla invented the Tesla coil, an air-cored, dual-tuned resonant transformer for generating very high voltages at high frequency. Audio frequency transformers (at the time called repeating coils) were used by the earliest experimenters in the development of the telephone. While new technologies have made transformers in some electronics applications obsolete, transformers are still found in many electronic devices. Transformers are essential for high voltage power transmission, which makes long distance transmission economically practical. This advantage was the principal factor in the selection of alternating current power transmission in the "War of Currents" in the late 1880s. Many others have patents on transformers.

INTRODUCTION

A TRANSFORMER is a device that transfers electrical energy from one circuit to another by electromagnetic induction (transformer action). The electrical energy is always transferred without a change in frequency, but may involve changes in magnitudes of voltage and current. Because a transformer works on the principle of electromagnetic induction, it must be used with an input source voltage that varies in amplitude. There are many types of power that fit this description; for ease of explanation and understanding, transformer action will be explained using an ac voltage as the input source. You learned that alternating current has certain advantages over direct current. One important advantage is that when ac is used, the voltage and current levels can be increased or decreased by means of a transformer. As you know, the amount of power used by the load of an electrical circuit is equal to the current in the load times the voltage across the load, or P = EI. If, for example, the load in an electrical circuit requires an input of 2 amperes at 10 volts (20 watts) and the source is capable of delivering only 1 ampere at 20 volts, the circuit could not normally be used with this particular source. However, if a transformer is connected between the source and the load, the voltage can be decreased (stepped down) to 10 volts and the current increased (stepped up) to 2 amperes. Notice in the above case that the power remains the same. That is, 20 volts times 1 ampere equals the same power as 10 volts times 2 amperes.
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How electricity is transported

The actual transmission of that power isnt straightforward at all. To begin with, the wires used in power lines are less than perfect conductors of electricity. Along any given length of wire there are all sorts of imperfections in the metal, and these tend to resist the flow of electrical current. These imperfections will always exist to some extent, even with the best manufacturing techniques and quality control, and the longer the power line, the more resistance the power flow will meet. The result is loss of electrical power. To address the problem of power loss electric utilities use step-up transformers, similar to the one in Figure 1. This enables voltage produced by the generator at the plant to be raised to a higher voltage, in turn enabling it to travel longer distances and remain effective.

Figure 1 Electricity Leaving the Power Plant Goes Through a StepUp Transformer For example, lets say that an electric generator puts out 12,000 volts, and a step-up transformer raises that to 765,000 volts (for example), enabling transmission to customers far away. With electrical transformers, there is an inverse relationship between voltage and current. So, when a step-up transformer increases input voltage, it actually results in a lowering of electrical current. So how does this phenomenon aid in power transmission? Simply put, when there is less current flowing through the wires, there is an accompanying reduction in power loss over the long length of the transmission line. Lets take a look at what happens when the power reaches our homes. Figure 2 shows a simplified distribution route from the power plant.
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Figure 2 A Step-Down Transformer is Used to Supply Electric Utility Customers First, the higher voltage originating from the step-up transformer at the power plant is decreased by the use of a step-down transformer located in a substation many miles away at the other end of the transmission line. The use of this intermediary step-down transformer effectively lowers the voltage and at the same time raises the current at the other end of the line, the end where customers are waiting to use. The path that the power follows is somewhat circuitous, but well planned out, with numerous strategically positioned distribution lines acting as the final leg of delivery. These distribution lines do what their name implies; they weave their way along streets and alleys, finally distributing electricity to customers. A step-down transformer located in a substation along the power transmission route allows this all to happen. It can readily convert the 765,000 volts being sent by the power plant to the 25,000 volts needed to feed distribution power lines. These, in turn, power individual homes, hospitals, etc. Now you obviously cant plug a television into a 25,000 volt wall outlet located in your house, so another step-down transformer is required to temper it into power thats both usable and safe. The one in our diagram is mounted on a nearby utility pole, and its job is to lower the 25,000 volts which it receives into a more manageable 240 and 120 volts, which is then fed into your home.

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BASIC PRINCIPLE
An ideal step-down transformer showing magnetic flux in the core. The principles of the transformer are illustrated by consideration of a hypothetical ideal transformer consisting of two windings of zero resistance around a core of negligible reluctance. A voltage applied to the primary winding causes a current, which develops a magneto motive force (MMF) in the core. The current required to create the MMF is termed the magnetizing current; in the ideal transformer it is considered to be negligible. The MMF drives flux around the magnetic circuit of the core.

Fig: (2.1) Step-down transformer showing magnetic flux

An electromotive force (EMF) is induced across each winding, an effect known as mutual inductance. The windings in the ideal transformer have no resistance and so the EMFs are equal in magnitude to the measured
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terminal voltages. In accordance with Faraday's law of induction, they are proportional to the rate of change of flux:
and

where:

and are the induced EMFs across primary and secondary windings, and are the numbers of turns in the primary and secondary windings, and are the time derivatives of the flux linking the primary and secondary windings.

In the ideal transformer, all flux produced by the primary winding also links the secondary and so , from which the well-known transformer equation follows:

The ratio of primary to secondary voltage is therefore the same as the ratio of the number of turns alternatively, that the volts-per-turn is the same in both windings.

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Transformer Construction
There are two general types of transformers 1. Core type transformer 2. Shell type transformer These two differ by the manner in which the windings are wound around the magnetic core. The magnetic core is a stack of thin silicon-steel laminations about 0.27 mm(or as specified before) thick for 50 Hz transformer. In order to reduce the eddy current losses, these laminations are insulated from one another by thin layers of varnish. In order to reduce the core losses, transformers have their magnetic core made from cold-rolled grainoriented sheet steel (C.R.G.O). This material, when magnetized in the rolling direction, has low core loss and high permeability.

Core Type Transformer:

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Fig: (3.1) Core-type Transformer

In the core-type, the windings surround a considerable part of steel core as shown in fig (a). The core type transformers require more conductor material and less iron when compared to shell-type. The vertical portions of the core are usually called limbs or legs and the top and bottom portions are called the yoke. For single phase transformers, core-type has two legged core. In order to reduce leakage flux, half of the L.V. winding is placed over one leg and other half over other leg. For H.V. winding also, half of the winding is placed over one leg and the other half over the other leg. L.V. winding is placed adjacent to the steel core and H.V. winding outside, in order to minimize the amount of insulation required.

Shell Type Transformer:

In the core-type, the steel core surrounds a considerable part of the windings as shown in fig (b). Shell-type transformer has three legged core. The L.V. and H.V. windings are wound on the central limb. In order to reduce leakage flux, the windings are interleaved or sandwiched. The shell type transformers require more iron and less conductor material when compared to core-type. There are two types of windings employed for transformers. 1. Concentric coils.
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2. Interleaved coils. The concentric coils are used for core-type transformers and interleaved coils for shell type transformers.

Fig: (3.2) Shell type transformer

Construction in which the iron circuit is surrounded by windings and forms a low reluctance path for the magnetic flux set up by the voltage impressed on the primary. Fig (1), Fig. (6) and Fig. (7) Shows the core type

Fig: (3.3) Core type 19

The core of shell type is shown Fig.(2), Fig.(3), Fig.(4), and Fig. (5), in which The winding is surrounded by the iron Circuit Consisting of two or more paths through which the flux divides. This arrangement affords somewhat Better protection to coils under short circuit conditions. In actual construction there are Variations from This simple construction but these can be designed With such proportions as to give similar electrical characteristics.

Fig: (3.4) shell type

Fig: (3.5) Single phase Transformer

Fig: (3.6) Single phase Transformer.

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Fig: (3.7) 3- phase Transformer Shell type

Fig: (3.8) 3- phase Transformer core type

Fig: (3.9) Cross section of a three-phase Distribution Transformer (Core Type)

Three-phase Transformers usually employ three-leg core. Where Transformers to be transported by rail are large capacity, five-leg core is used to curtail them to within the height limitation for transport.

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Before going into depth of Manufactring Process, we shall now discuss on the processing of three major raw materials which constitute about 70 percent of cost of transformer. They are: a) CRGO (Cold Rolled Grain-Oriented) silicon steel b) Winding wires and strips c) Oil The purpose of discussing these raw materials is to know how the qualities of raw materials influence the performance of the transformer. The right choices of materials also improve the performance.

TRANSFORMER CORE
Grain oriented Electrical Steel CRGO is undoubtedly the most important soft magnetic material in use today. Whether in small transformer, distribution transformer or in large transformer & generator, grain oriented electrical steel CRGO is a must for the production of energy saving electrical machines. Grain oriented Electrical Steels are iron-silicon alloys that provide low core loss and high permeability needed for more efficient and economical electrical transformers. CRGO Grain oriented grades of electrical steel are typically used for transformer cores and large generators The magnetic core is built up of laminations of high-grade silicon sheet steel, which are insulated from each other by a special coating of varnish. The usual thickness of laminations is 0.18mm, 0.23mm, 0.27mm, 0.30mm and 0.35mm. The two losses, due to varing flux, occur in the core: the eddy current and the histeresis losses. The silicon content of the iron and the nature of annealing are very important I determining the histeresis loss. Silicon makes the material very brittle, thus making it difficult to process.
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Distribution transformers can achieve low no-load losses by using cores made with low-loss high-permeability silicon steel or amorphous (non-crystalline) metal alloy. The higher initial cost of the core material is offset over the life of the transformer by its lower losses at light load. NOTE: - In India distribution transformers are mainly manufactured with 0.27 mm materials (0.27-M-4). But in order to minimise losses, the following changes in grades may be conceived: To reduce losses, 27-M4 may be replaced by HI-B-0.27, affecting a reduction of 16%. Similarly, losses may be further reduced by 8% by replacing HI-B-0.27 with HI-B-0.23. Nowadays laser grade ZDMH-0.23 is available which has a superior property of 14% over HI-B-0.23. It can be seen from the above that by using a better grade of materials, the losses can be reduced to (16+ 8+ 14) =38% than that of conventional core transformers, being designed previously with 27-M4 grade CRGO. The reduction of losses not only minimises the running cost, it also helps to reduce the core frame size, thereby reducing the cost of winding as well as the oil. One can design a more cost-effective, low-loss, energy efficient transformer by incorporating the above grade of materials.

TECHNICAL DETAILS:
CRGO or Cold Rolled Grain Oriented Steel is available in various grades (generally called M3, M4, M5& M6). Major international standards such as Japanese (JIS), American (ASTM), German (DIN) and British Standards are given in table 1 which specify grade, thickness, Watt Losses and Magnetic Flux density. IMPORTANT ELECTRICAL PROPERTIES OF CRGO
Table 1 - Grain Oriented Electrical Steel strips
Japanese JIS C 2553 (1986) Classification Density Thickness (kg/dm) Symbol mm 27 P 100 7.65 27 P 100 27 G 120 0.27 27 G 130 27 G 140 30 P 110 0.30 30 P 120 30 G 130 Iron Loss (W/kg) W17/50 1.00 max. 1.00 max. 1.20 max. 1.30 max. 1.40 max. 1.10 max. 1.20 max. 1.30 max. Magnetic Flux Density (T) B 1.85 1.78 1.75 1.85 1.78

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30 G 140 30 G 150 35 P 125 35 P 135 35 G 145 35 G 155 35 G 165

0.35

1.40 max. 1.50 max. 1.25 max. 1.35 max. 1.45 max. 1.55 max. 1.655 max.

1.75 1.85 1.78 1.75

British BS 601 Part 2 (1973) Maximum specific total loss at a peak magnetic flux density of 1.5T and a frequency of 50 Hz. Grade 35M6 30M6 30M5 28M5 28M4 Maximum specific total loss W/kg 1.11 1.07 0.97 0.95 0.89

USA AISI ( 1983 ) MAXIMUM CORE LOSSES - Electrical Steels Grain Oriented Full Processed ASTM A665 Maximum Core Loss at 15 kg (1.5 T) ASTM Former Thickness Type AISI W / lb W /kg Type Inch mm 60Hz 50Hz 60Hz 50Hz 27G053 M-4 0.0106 0.27 0.53 0.40 1.17 0.89 30G058 M-5 0.0118 0.30 0.58 0.44 1.28 0.97 35G066 M-6 0.0138 0.35 0.66 0.50 1.46 1.11

IMPORTANT PHYSICAL PROPERTIES OF CRGO

Density gm/c3 Silicon content % Resistivity micro Ohm-centimeter Ultimate Tensile Strength 0 to Rolling Direction Kg/mm2 Ultimate Tensile Strength 90 to Rolling Direction Kg/mm2 Stacking factor % M4 (.27 mm) Stacking factor % M5 (.30 mm) Stacking factor % M6 (.35 mm) 7.65 3.10 48.00 32.60 38.20 96.00 96.50 97.00

CRGO materials come either in the form of coils or sheets. Table 2 gives details of dimensions and tolerances as per JIS C 3553.

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DIMENSIONS & TOLERANCES

0.18 mm (0.0071 in. ) 0.20 mm (0.0079 in.), 0.23 mm (0.0091 in. ) 0.27 mm (0.0106 in.), 0.30 mm (0.0118 in. ) 0.35 mm (0.0138 in.) 914 mm (36 in.), and 1000 mm (39 in. ) from 50 mm(2 in.), to 1.050mm (41 in. ) 508 mm (20 in. ) 0.30 mm (0.0118 in.), 0.35 mm (0.0138 in. ) 914 mm (36 in.), and 1000 mm (39 in. ) Length will be available according to negotiation

Thickness COILS Width (Standard width available with range) Inside Coil Diameter Thickness Width Length

Sheets

Tolerances in Dimensions & Shape - conform to JIS C 2553.

TOLERANCE Camber in Deviation of any 2 Width Thickness thickness in Thickness Width metres mm mm transverse Shear Burr mm mm mm (Slit direction Products) mm mm 0.18 +0.02 0.20 +0.02 150 0.23 +0.02 or 0.02 or under +0.20 0.27 +0.03 under 0.30 +0.03 0.35 +0.03 0.18 +0.02 0.20 +0.02 over 0.23 +0.02 0.02 150 +0.30 0.27 +0.03 or under to 400 0.30 +0.03 0.35 +0.03 1.0 or 0.05 under or unde 0.18 +0.02 0.20 +0.02 over 0.23 +0.02 0.03 400 +0.50 0.27 +0.03 or under to 750 0.30 +0.03 0.35 +0.03 0.18 +0.02 0.20 +0.02 over 0.23 +0.02 0.03 +0.6 750 0.27 +0.03 or under 0 0.30 +0.03 0.35 +0.03

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Besides the Watt Losses at specific flux densities of 1.5 T and 1.7 T CRGO manufacturers also give curves of indicating Watt Losses ad A.C. Magnetization at various flux densities. These curves are of immense help to Transformer designers, and available on request. Conventional CRGO materials (M4, M5, M6) are used regularly for cores in Transformers. However recently due to environmental protection, energy savings are becoming a very important factor and minimizing care loss in Transformers is becoming a must. Nippon Steel Corporation has come out with low loss Hi-B materials, which guarantee low Watt Losses at 1.5 Tesla flux density. Such materials are called Hi-B materials. Table 3 gives magnetic properties of Hi-B material. Popular Hi-B grades used in India are 23 MOH & 27 MOH Watt.

Hi - B CRGO MATERIALS:
Thickness mm mil Core Loss Lamination Factor Max. Typical Typical Typical Grade W W W W W B (T) % (W/Kg) (W/Kg) (W/Kg) (W/Kg) (W/Kg) 23ZDKH85 0.85 0.57 0.78 0.34 0.46 1.91 97.5 23ZDKH90 0.90 0.58 0.80 0.35 0.48 1.91 23ZDMH85 0.85 0.57 0.78 0.34 0.46 1.91 97.4 23ZDMH90 0.90 0.59 0.81 0.35 0.48 1.91 23ZH90 0.90 0.63 0.87 0.37 0.51 1.92 23ZH95 0.95 0.64 0.90 0.38 0.53 1.92 97.7 23M-OH 1.00 0.66 0.93 0.39 0.54 1.92 27ZDKH90 0.90 0.62 0.84 0.38 0.53 1.92 98.0 27ZDKH95 0.95 0.65 0.88 0.39 0.52 1.91 27ZDMH90 0.90 0.62 0.84 0.38 0.53 1.91 97.9 27ZDMH95 0.95 0.65 0.88 0.39 0.53 1.91 27ZH95 0.95 0.69 0.93 0.41 0.55 1.91 27M-OH 1.03 0.72 0.99 0.43 0.59 1.91 98.1 27M-1H 1.09 0.74 1.03 0.44 0.61 1.91 30ZH100 1.00 0.73 0.98 0.44 0.58 1.92 98.3 30M-OH 1.05 0.74 1.01 0.44 0.60 1.91 35M-1H 1.16 0.85 1.13 0.52 0.68 1.92 98.5 35M-2H 1.22 0.90 1.19 0.54 0.73 1.92

0.23

0.27 11

0.30 12 0.35 11

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A. K. Steel Corp. of USA ( formally ARMCO) has also come out with their own brand of low loss CRGO called Trancor H-0 and Trancor H-1. The Watt Losses are as follows : CORE LOSSES
ARMCO TRAN. CORE (TC) TC H0 TC H1 TC H2 THICKNESS INCHES (mm) .009 ( .23 ) .011 ( .27 ) .012 ( .30 ) TYPICAL WATTS WATTS WATTS PER PER KG 60 PER KG 50 KG Hz Hz @ 1.7 T/50 Hz 1.7 T 1.7 T T 1.32 1.46 0.90 1.00 1.05 0.80 0.90 0.95

CRGO steel processing:

After slitting the next operation in CRGO processing is Mitring and subsequently, knotching. Earlier of laminations in shape where flux had to travel from strip to other by right (90 angle). As has been indicated. The flux generated in the limb travels along the direction of rolling. When it enters the top lamination. It faces a cross grain till flux rotates by 90 and thereby produces high reluctance, causing high magnetic loss. These days, with the availability of improved processing equipments and modern technology, the laminations are being cut at an angle of 45, causing a rotation of flux by only 45. The reduction in angle of rotation of flux from 90 to 45 causes an achievement of less reluctance. With an effect of a reduction in the magnetic loss.

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The rotation of flux and the cutting angle have been shown in figure

Fig: (4.1) rectangular cut lamination

Fig: (4.2) Miter-cut lamination

This particular procedure of cutting the CRGO laminations is commonly known as Miter-cut. The top and bottom laminations are cut as v at the center, thereby creating a knotch to receive the centre leg laminations as shown figure. Since the continuous operation of cutting the steel sheet is required while processing CRGO laminations, one has to remain very vigilant on the sharpness of cutting tools; otherwise, it will produce a good amount of burr on the cutting edges. The acceptable limit of burr on the cutting edges should be limited to 30 to 40 microns. More of burr would add more air-gaps in the core assembly, causing more no-load-losses, despite using good quality CRGO material.

Core building
Slitting - For building the transformer cores, laminations sheets of different widths and packet heights are needed. The manufacturing schedule may include cores of different diameters and different types of constructions necessitating slitting laminations in many widths and lengths. CRGOS rolls cannot be ordered in so many different widths and quantities. Various types of core stackings for three-phase transformers have commonly been adopted during manufacturing. Some core building schemes have been show in fig. which are, however, only representative examples.

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Each scheme has its own advantages and limitations. The designer should look into the applicability of the scheme before going for the final design of core laminations. Core building from the finished lamination sheet is done in horizontal position on specially raised platforms. The lamination sheets are susceptible to mechanical stresses of bending, twisting, and impact. A lot of care is taken while handling and normally two persons are needed to hold the two ends of laminations at the time of laying. Steel bands are used for tightening the lamination is only a temporary arrangement and are later removed. To hold the leg laminations resiglass tapes, are tightly wound around the legs at specified pitch and cured by heating, this tape shrinks after heating and provides a firm grip. Step-lap Apart from the models of core building schemes shown above, there is one more scheme of construction, commonly known as step-lap construction.

The construction of step-lap may be of cross-step or longitudinal step. This type of core building scheme has a specific advantage over other schemes, especially towards magnetic properties. Step-lap core assembly emits less no-load loss than conventional assembly. But in India, step-lap core construction is very popular, since the cost of the processing equipment is huge and it is beyond the reach of small scale units. The equipment is known as automatic cut-it length line, CNC control.

Selection of the Core Diameter:

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Based on the requirement of no-load loss and no-load current, a suitable working flux density. In India, PSEB, HPSEB, DVB etc. have restricted the choice of flux density at rated voltage and frequency to 1.6 tesla(maximum), where RSEB and UPPCL have restricted the same to 1.69 tesla (maximum) Once the number of turns and flux density are known, the gross core area may be calculated by using the formula: Et=phase voltage turns =4.44fBmAg0.9710-4 Where, f is the rated frequency which is 50 Hz (known) Bm is the maximum flux density in tesla(known) Ag is the gross core area in sqcm (to be calculated) 0.97 is the stacking factor (assumed) From the above equation, the gross core area can easily be calculated. Once the gross area Ag is known, the approximate core diameter can be calculated by using the following formula: Ag=K1d2/4 Where,K1 is a factor to be selected on the basis of the number of core steps and d is the required core diameter we are looking for. The approximate value of K1 may be assumed as follows: For 6 steps, the approximate value of K1=0.92 For 7 steps, the approximate value of K1=0.925 For 8 steps, the approximate value of K1=0.93 For 9 steps, the approximate value of K1=0.935 For 10 steps, the approximate value of K1=0.94 For steps 11 steps, the approximate value of K1=0.945

Core Assembly:

The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO) Silicon Steel It is in the form of thin sheets & cut to size as per design, as it is shown in the design specification sheet. (refer case-study for design sheet so that you can understand) Generally three different shapes of core laminations are used in one assembly. Notching is performed to increase the magnetic path. The laminations are put through annealing process. These laminations are assembled in such a manner that there is no air gap between the joints of two consecutive sheets.
30

The entire assembly is done on a frame commonly known as core channel. These frames being used as a clamping support of the core assembly.

Winding Wires and Strips

Like CRGO laminations, winding wires and strips are also a vital raw materials used in transformers, the basic material available in the market are in form of rods having a varying diameter from 8mm to 16mm. the rod is drawn to the required designed sizes and then insulated with paper or other insulating materials. Annealing or heat treatment is also done on drawn materials for softening and stress relieving.

31

Fig: (5.1) Wires & strips

Basic material and their processing:

Because of its low conductivity and higher resistivity, an aluminium conductor occupies almost double the volume than that of copper winding and hence, an aluminium-wound transformer always looks bigger in size than a copper-wound transformer of same KVA rating. Aluminium-wound transformer came into service in early 1970s after REC formulated a revised specification for transformer up-to, and including, 100KVA ratings. Even after long use of almost 30years, we are yet to come with a conclusion about the superiority of copper-wound transformer over Aluminium-wound transformer will give equal , if not better, service than a copper-wound transformer.

Paper covering on the conductors:

Paper-insulated wires and strips are used in oil-filled transformers and other allied electrical machines.

Fig: (5.2) Paper covered conductors

In the case of double paper covered conductors, tow slitted papers are used, wrapped in opposite directions. However, if more than two papers are used, than all the papers shell be overlapped and wound in the same direction, unless otherwise specified.
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Test on paper covered conductor (a) Bare size (b) Covered size (c) Resistance (d) Tensile strength (e) Overlap (f) Oil absorption test (g) Corner radius of strip (h) Electric strength proof test Reference ISS for Wires and Strips (a) Insulated aluminium wire (b) Insulated aluminium strip (Part-2). (c) Insulated copper wires and strip -2). (d) Insulated copper strips (Part-2). (e) Test method

- Physical check. - Physical check. - Electrical check. - Mechanical check. - Physical check. - Mechanical check. - Mechanical check - Electrical check. - IS-6162 (Part-1). - IS-6160 and IS-6162 - IS-7404 (Part-1 and - IS-6160 and IS-7404 - IS-10452 (Part-1).

Insulation paper:
Electrical Grade insulation papers (EGIP) are generally used for covering the bar conductors. EGIP has certain technical superiority pertaining to their usability as insulation in electrical requirements. These have: (a) Flexibility; (b) Easy to use; (c) Higher insulation with lesser thickness; (d) Higher resistance to oil; (e) Reasonable heat resistance; (f) Lower chloride impurities. Because of the above properties, the EGIP finds wide-range usage in insulated wires and strips for oil-immersed transformers and certain other electrical equipments.

33

Fig: (5.3) Insulating paper

The EGIP are available in various widths, the jumbo roll is further slitted to various sizes in shape of small discs. The paper is slitted into various widths, depending upon the number of coverings required on the conductors. The width of slit also depends on the factor of over-lapping.

Choice of using chopper or aluminium as winding material:

The choice of using copper or aluminium as winding material generally depends upon the end-users. Most of our power utilities in India desire transformers up to 250 KVA/11 KV with aluminium windings, because of its wide availability and economy in cost. But owing to some limitation in its inherent properties, higher rating transformers are made with copper winding. However, 22KV and 33KV distribution transformers are always made with copper windings only.

Selection of winding wires and strips:

Winding wires and strips are selected on the basis of the requirement of the current for which they have been designed. While selecting the size of a conductor, a design must keep in mind the winding material as well as the current density. To start with the preliminary design, the current density may be based on the following values: For aluminium windings: 1.5 A/sq mm (maximum). For copper winding: 3.0 A/sq mm (maximum). The selection of current density is sometimes restricted by the buyers also. For instance, in the case of aluminium-wound transformer, PSEB, UPPCL, HPSEB etc. restricted the current density to 1.5 A/sq mm. similarly, for a copper-wound transformer, the DVB has restricted the current density to 2.5A/sq mm, UPPCL to 2.8 A/sq mm and so on.

34

The rated current may be calculated on the basis of its KVA, number of phase and the rated voltage. KVA= Or I= For a 100kva transformer having voltage ratio 11000/433 V with delta/star connection, the secondary current per phase (being star connected)is: I= Similarly, the primary line current = = =3.03A = 5.25A . VI (for three-phase transformer)

Since the primary winding is delta connected, the phase current is Once the current is known, the conductor area may be calculated on the basis of assumed current density: Conductor area =

Selection of number of turns:

The number of turns of a transformer is directly related to its KVA rating and is approximately calculated by the formula: =KQ Where, is the voltage per turn. Q is the rated KVA. K is the factor to be decided. For instance, k for aluminium-wound transformer may be taken in the range of 0.32 to 0.35, where as, it is between 0.37 and 0.45 for copper-wound transformer. The value of k has been shown as reference only. However, any other value beyond this limit may also be selected for working out a preliminary design. Based on any assumed value of k, a preliminary design is worked out. All performance figures like losses, impedance, resistance etc. are calculated and compared with the guaranteed values. In case of any
35

difference between the calculated values and the guaranteed values, a separate re-run is done with a revised value of k.

Calculations of size of a high-voltage conductor:

For distribution transformer of medium capacity, the conductors being chosen for primary winding are mostly round in shape and the diameter of round conductors may be calculated from the available conductor area. Conductor area = Where, d is the bare diameter of a high voltage conductor. The diameter of winding wire as has been calculated above may be further revised from the standard table available in IS-6162. In case the diameter of equipment area may be selected instead of a round conductor. Obviously, an equipment rectangular strip will show better results than a thick, round conductor. While selecting the conductor, one has to take care of the available conductor surface area as well as the space factor. A thick round conductor has poor surface area as well be as poor space factor. This can very well be illustrated by way of the following examples:
Comparison of space factor of round and rectangle conductors

Cross-sectional area surface length space factor

Round conductor of diameter: 3.6 mm d/4=10.18sqmm d=11.3mm 1.27

Equivalent strip 61.7 mm 10.2 sq mm LB2=15.4 mm 1.0

From the above, we may conclude that the equipment rectangular strip has a better surface length and 27 percent more space factor that of a round conductor.

Calculation of size of a low-voltage conductor:

In case of low-conductor since the current is generally high; a rectangular conductor is commonly used. Multiple strips in parallel are also selected for a higher rating transformer. The selection of the size of strips plays a very vital role on the performance of
36

a transformer. Current has a tendency to flow through the surface of the conductor. This is commonly known as a skin effect. One has to be very selective while making the final choice of the strip. The mode of selection of a strip may be well justified with the following calculations. For example , if we are looking for a strip having a cross-sectional area of 54 sq mm, an equivalent size of the strip may be taken as 96 as shown in figure

Fig: (5.4) Rectangle strip of low-voltage winding

The total surface length of this strip=29+6=30mm. As an alternative of the above strip, two parallel strips may be taken, each having a size of 93mm as shown in the figure. The equivalent cross-section area of the alternative conductor =2 (93) =54 sq mm, which is the same as that of the original strip. But this alternative strip is definitely better than the single strip in respect of surface length. The surface length of the alternative strip: 29+3=48mm, which is about 1.6 times more than the first choice? This is one of the reasons for using more rectangular strip in parallel rather than thick, single strip. The use of two parallel strips is definitely a better option than a single thick strip in respect of skin effect. This can be tabulated too.

Table: Comparison of a single thick strip with multiple strips in parallel. In respect of surface length

Description Cross-section area

Strip size 96mm 54 sq mm

Alternative Remarks Strip size 2 nos. (93)mm 54 sq mm Both are equal.

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Surface length Ratio of length surface

30 mm _

48 mm 48/30=1.6 times

The alternative Strip has a better surface length. Skin effort on the alternative strip will be reduced. Yielding less stray loss.

Maximum depth of a strip In general, the depth of a strip should not be more than half of the strip width, which means, if the width of a strip is 9mm, its depth should not be more than 4.5 mm in any case. Therefore, we may write width/depth 2 Minimum depth of strip However, there is a limitation of minimum depth with respect to the width of the strip as 1:6. But for all practical purposes, we should narrow down the ratio further to 1:4, which means the minimum depth should be 9/4=2.25mm or more. This restriction is mainly because of the limitation of drawing of strips during processing. Therefore, we may write width/depth 4

Transposition:
In case of coil has been designed with more then one strip and if the strips are placed one above the other, then the transposition is must. In the case of a non-transposed coil, the strip placed below (no: 2) will have a comparatively lower mean length than that of the upper stripe (no: 1). In such case, since the lengths of the two strips are different, the resistance will be different too. When two such strips of unequal
38

resistance are placed in parallel, the strip placed below will have greater share of the current because of its low resistance, while the strip placed above will share less current due to its high resistance. The purpose of transposing the strips is to make the length of the strips almost similar, there by making the resistances of both the strips equal. Distribution of current among the parallel strips of a properly transposed coil will be equal, making it advantageous over the nontransposed coil. Moreover, transposition is almost done to minimize the leakage reactance. A non-transposed coil is one of the reasons to yield more reactance than the calculated design value. As the following figure shows the nature of transposition.

Fig: (5.5) Transposition

Insulation design: Transformer winding have insulation with in the winding, between windings and windings to earth. Insulation with in winding is generally paper insulation, however helical and disc type of winding has ducts between turns or discs. Paper thickness should be such that it should be able to withstand various voltage stresses appearing during normal and transient condition. Some times paper thickness is increased on pretransposed cable of large cross sectional area, to increase the paper strength of paper insulation. Electrical clearances between windings of various voltage class and winding to earth dependent upon their BIL and insulation arrangement adopted. Various clearances and disposition of solid insulation should be such that adequate cooling ducts are available to have effective cooling of windings. Also voltage stresses are controlled with in limits.

Tap-changer Voltage variation in electrical system is a normal phenomenon, because of rapid growth of industries and distribution network. It is very essential to maintain the system voltage with in prescisabed limit for better health of electrical equipments. Voltage of the system can be varied by changing the turns ratio of transformer. The device tapchanger is used for adding
39

or cutting out turns of primary or secondary winding of the transformer. Generally tapchanging equipments are of two forms: Off-circuit tapchanger, On-load tap changer. Off-circuit tapchanger is the cheapest method of changing the turn ratio. For this it is essential to de-energize the transformer before tapchanging. On-load tapchanger are employed to change turn ratio of transformer to regulate system voltage while the transformer is delivering normal load. With the introduction of on-load tapchanger, the operating efficiency of electrical system has considerably improved. Now-a-days almost all the large transformers are fitted with on-load tapchanger.

Transformer oil
Transformer oil or insulating oil is usually a highly-refined mineral oil that is stable at high temperatures and has excellent electrical insulating properties. It is used in oil-filled transformers, some types
40

of high voltage capacitors, fluorescent lamp ballasts, and some types of high voltage switches and circuit breakers. Its functions are to insulate, suppress corona and arcing, and to serve as a coolant. Explanation: The oil helps cool the transformer. Because it also provides part of the electrical insulation between internal live parts, transformer oil must remain stable at high temperatures for an extended period. To improve cooling of large power transformers, the oil-filled tank may have external radiators through which the oil circulates by natural convection. Very large or high-power transformers (with capacities of thousands of KVA) may also have cooling fans, oil pumps, and even oil-to-water heat exchangers. Large, high voltage transformers undergo prolonged drying processes, using electrical self-heating, the application of a vacuum, or both to ensure that the transformer is completely free of water vapour before the cooling oil is introduced. This helps prevent corona formation and subsequent electrical breakdown under load. Oil filled transformers with a conservator (an oil tank above the transformer) tend to be equipped with Buchholz relays. These are safety devices that detect the build up of gases (such as acetylene) inside the transformer (a side effect of corona or an electric arc in the windings) and switch off the transformer. Transformers without conservators are usually equipped with sudden pressure relays, which perform a similar function as the Buchholz relay. The flash point (min) and pour point (max) are 140 C and 6 C respectively. The dielectric strength of new untreated oil is 12 MV/m (RMS) and after treatment it should be >24 MV/m (RMS).

Transformer Oil Testing:

Transformer oils are subject to electrical and mechanical stresses while a transformer is in operation. In addition there are contaminations caused due to chemical interactions with windings and other solid insulations, catalyzed by high operating temperature. As a result the original chemical properties of transformer oil changes gradually, rendering it ineffective for its intended purpose after many years. Hence this oil has to be periodically tested to ascertain its basic electrical properties, and make sure it is suitable for further use or necessary actions like filtration/regeneration has to be done. These tests can be divided into:
41

1. 2. 3. 4.

Dissolved gas analysis Furan analysis PCB analysis General electrical & physical tests:

Colour & Appearance Breakdown Voltage Water Content Acidity (Neutralization Value) Dielectric Dissipation Factor Resistivity Sediments & Sludge Interfacial Tension Flash Point Pour Point Density Kinematic Viscosity

The details of conducting these tests is available in standards released by IEC, ASTM, IS, BS, and testing can be done by either of the methods. The Furan and DGA tests are specifically not for determining the quality of transformer oil, but for determining any abnormalities in the internal windings of the transformer or the paper insulation of the transformer, which cannot be otherwise detected without a complete overhaul of the transformer. Suggested intervals for these tests are: General and physical tests - bi-yearly Dissolved gas analysis yearly Furan testing - once every 2 years, subject to the transformer being in operation for min 5 years.

Various type of cooling

ONAN type cooling: The generated heat can be dissipated in many ways. In case of smaller rating of transformers, its tank may be able to dissipate the heat
42

directly to the atmospheric air, while bigger rating require additional dissipating surface in the form of tube or radiators connected to tank or in the form of radiator bank. In these cases the heat dissipation is transformer oil to atmospheric air by natural means. This form of cooling is known as ONAN (oil natural, air natural) type cooling. Normally this type of cooling is employed in Distribution transformers (as this is economical) ONAF type cooling: In this type fans blowing on to the cooling surface are employed. The forced air takes away the heat at faster rate, thus gives better cooling rate than natural air. This type of cooling is called ONAF (oil natural, air forced) type of cooling. Generally this type of cooling system is employed in higher rating transformers like Station transformers. OFAF type cooling: Better rate of heat dissipation could be obtained if in additional to forced air, means to force circulating the oil are also employed. The oil can be forced with in the closed loop of transformer tank and the cooling equipment by means of oil pumps. This type of cooling is called OFAF (oil forced, air forced) type of cooling. As this type of cooling is employed in high rating transformers like power transformers.

Radiators:
Transformers need to dissipate the heat they generate during operation to keep efficiency. Such heat dissipation (cooling) in mainly obtained via external radiators. There are two basic Transformers radiators designs currently available on the market: Stamped-plate: such radiators are made of stamped steel and have a traditional design Tubular radiators: the ribs of such radiators are made of ERW (welded) tubes, instead of stamped plate. This design has been introduced and patented on the market in 1979 by a Partner European Manufacturer and more than 100.000 units have been so far installed throughout the world. This technology is well consolidated and currently used by major transformers manufacturers.

The main advantages of the tubular design over stamped-plate are: The tubular design has a, proven, STRONGER HEAT DISSIPATION POWER than stamped plate radiators. All studies and analysis conducted over the past 30 years, plus the empirical

43

experience, have demonstrated that tubular radiators have a 25%/ 30% stronger heat dissipation efficiency than stamped plate radiators at surface parity. This means that a tubular designed radiator requires 30% less surface than a stamped plate radiator to guarantee the required heat dissipation. So, for instance, the same dissipation of a 1000m2 stamped steel radiators package is guaranteed by a 700 m2 package of tubular radiators. Given this important advantage, tubular radiators REQUIRE LESS STEEL TO BE BUILT. As a consequence: tubular radiators are circa 35% LIGHTER (easier transportation) and generally CHEAPER than stamped steel radiators. Tubular radiators REQUIRE -40 / -50 % OIL to function compared to standard stamped plate radiators. This is a tremendous cost advantage that should be accounted for when comparing the cost of a tubular vs stamped plate radiator. Not only the tubular radiator is generally cheaper, given its lightness, but the transformer requires 40% / 50% less oil to function, with an immediate economic advantage both for the manufacturer and end-user (during the life cycle of the transformer). Considering a 40 MVA transformer, for instance, while a tubular designed radiator requires 3.200 kg of oil to function, a stamped plate radiator requires more than 7.000 kg. Tubular radiators are MECHANICALLY ROBUST AND SOLID. Header, Caps and Ribs thicknesses (3mm, 1.5mm, 1.1 mm) have been calculated to ensure extraordinary solidity especially under working conditions, i.e. filled radiators. Any additional requirement (examples ribs thickness > 1.1 mm) may be satisfied.

Fig: (7.1) Stamped-plate

Fig: (7.2) Tubular

Protecting Devices
Bushings:
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A bushing is a hollow insulating liner through which a conductor may pass. Bushings appear on switchgear, transformers, circuit breakers and other high voltage equipment. Description The bushing is a hollow insulator, allowing a conductor to pass along its centre and connect at both ends to other equipment. Bushings are often made of wet-process fired porcelain, and may be coated with a semi-conducting 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 directcurrent converters.

Fig: (8.1) Bushing

Surge Arresters A lightning arrester is a device used on electrical power systems to protect the insulation on the system from the damaging effect
45

of lightning. Metal oxide varistors (MOVs) have been used for power system protection since the mid 1970s. The typical lightning arrester also known as surge arrester has a high voltage terminal and a ground terminal. When a lightning surge or switching surge travels down the power system to the arrester, the current from the surge is diverted around the protected insulation in most cases to earth. Arrester Selection The objective of arrester application is to select the lowest rated surge arrester which will provide adequate overall protection of the equipment insulation and have a satisfactory service life when connected to the power system. The arrester with the minimum rating is preferred because it provides the greatest margin of protection for the insulation. A higher rated arrester increases the ability of the arrester to survive on the power system, but reduces the protective margin it provides for a specific insulation level. Both arrester survival and equipment protection must be considered in arrester selection. The proper selection and application of lightning arresters in a system involve decisions in three areas: 1. Selecting the arrester voltage rating. This decision is based on whether or not the system is grounded and the method of system grounding. 2. Selecting the class of arrester. In general there are three classes of arresters. In order of protection, capability and cost, the classes are: Station class Intermediate class Distribution class The station class arrester has the best protection capability and is the most expensive. 3. Determine where the arrester should be physically located. Arrester Voltage Rating: The lower the arrester voltage rating, the lower the discharge voltage, and the better the protection of the insulation system. The lower rated arresters are also more economical. The challenge of selecting and arrester voltage rating is primarily one of determining the maximum sustained line-to-ground voltage that can occur at a given system location and then choosing the closest rating that is not exceeded by it. This maximum sustained voltage to ground is usually considered to be the maximum voltage on the unfaulted phases during a single line-to-ground fault. Hence, the appropriate arrester ratings are dependent upon the manner of system grounding. Arrester Class The class of lightning arrester to be applied depends upon the importance and value of the protected equipment, its impulse insulation level and the expected discharge currents the arrester must withstand.
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Station class arresters are designed for protection of equipment that may be exposed to significant energy due to line switching surges and at locations where significant fault current is available. They have superior electrical performance because their energy absorption capabilities are greater, the discharge voltages (protective levels) are lower and the pressure relief is greater. The value of the protected equipment and the importance of uninterrupted service generally warrant the use of station class arresters throughout their voltage range. Industry standards dictate the use of both station class and intermediate class arresters for equipment protection in the 5-to 20-mVA size ranges. Above 20 mVA, station class arresters are predominately used. Intermediate class arresters are designed to provide economic and reliable protection of medium voltage class power equipment. Intermediate arresters are an excellent choice for the 10protection of drytype transformers, for use in switching and sectionalizing equipment and for the protection of URD cables. Traditional applications include equipment protection in the range of 1 to 20 mVA for substations and rotating machines. Distribution class arresters are frequently used for smaller liquidfilled and dry-type transformers 1000 kVA and less. These arresters can also be used, if available in the proper voltage rating, for application at the terminals of rotating machines below 1000 kVA. The distribution arrester is often used out on exposed lines that are directly connected to rotating machines. Location of Arresters The ideal location for lightning arresters, from the standpoint of protection, is directly at the terminals of the equipment to be protected. At this location, with the arrester grounded directly at the tank, frame or other metallic structure which supports the insulated parts, the surge voltage applied to the insulation will be limited to the discharge voltage of the arrester. Practical system circumstance and sound economics often dictate that arresters be mounted remotely from the equipment to be protected. Often, one set of arresters can be applied to protect more than one piece of equipment. Low BIL apparatus (certain dry-type transformers and rotating machines) will often require surge protective devices be connected directly at the terminals of the equipment being protected. In many switchgear installations, the only exposure to lightning will be through a transformer located on its up stream side. When the transformer has adequate lightning protection on its primary, experience has shown that the surge transferred through the transformer is usually
47

not of a magnitude that would be harmful to the switchgear. Hence, it is generally not necessary to provide arresters in the switchgear. When arresters are located away from the terminals of the protected equipment, the voltage wave will reflect positively on the equipment terminals and the voltage magnitude at the terminal point will always be higher than the discharge voltage of the arrester. This, as discussed earlier, is due to the fact that the protected equipment usually has higher surge impedance than the line or cable serving it. If the circuit is open at the protected equipment (infinite surge impedance), the voltage will be double the arrester discharge voltage. The actual surge voltage appearing at the protected equipment depends, in part, on the incoming wave magnitude at the instant of arrester discharge. If a positive reflected surge from the protected equipment arrives back at the arrester before arrester discharge, it will add to the incoming wave to produce discharge at a lower incoming wave magnitude. The reflected wave, in this case, results in improved protection. The closer the arrester is to the protected equipment, the greater the effect of the reflected surge on arrester discharge and the better the protection. Buchholz Relay A Buchholz relay is a gas and oil operated device installed in the pipe work between the top of the transformer main tank and the conservator. A second relay is sometimes used for the tapchanger selector chamber. The function of the relay is to detect an abnormal condition within the tank and send an alarm or trip signal. Under normal conditions the relay is completely full of oil. Operation occurs when floats are displaced by an accumulation of gas, or a flap is moved by a surge of oil. Almost all large oil-filled transformers are equipped with a Buchholz relay, first developed by Max Buchholz in 1921. Conditions Detected A Buchholz relay will detect: Gas produced within the transformer An oil surge from the tank to the conservator A complete loss of oil from the conservator (very low oil level)

General Arrangement
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Front

View Rear

View

(Cover

Removed)

A - Gas Collection Chamber

B Upper Float C Lower Float D - Oil Surge Detector

Fig: (9.1) Buchholz relay

Fault conditions within a transformer produce gases such as carbon monoxide, hydrogen and a range of hydrocarbons. A small fault produces a small volume of gas that is deliberately trapped in the gas collection chamber (A) built into the relay. Typically, as the oil is displaced a float (B) falls and a switch operate - normally to send an alarm. A large fault produces a large volume of gas which drives a surge of oil towards the conservator. This surge moves a flap (D) in the relay to operate a switch and send a trip signal. A severe reduction in the oil level will also result in a float falling. Where two floats are available these are normally arranged in two stages, alarm (B) followed by trip (C).

Breather
A transformer breather is an accessory of an oil filled type transformer which is attached into the oil conservator tank; this serves as
49

the breathing point of the unit, that when the insulating oil of the transformer gets heated up, it expands and goes back to the conservator tank and subsequently pushes the dry air out of the conservator tank through the breather which is filled with silica gel, when the oil cools down, it retracts and sucks fresh air from the atmosphere through the breather and from this point, the silica gel dries up the air that goes back in to the conservator tank.
For a better understanding observe the following Figure:

Fig: (10.1) Breather

Step-By-Step Manufacturing Process of Oil-Cooled -Transformer

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1. 2. 3. 4. 5. 6.

Coil Winding Core Assembly Core-Coil Assembly Tank-up Transformer Tank Painting & Finishing Coil Winding

1. High Voltage Coils: H.V. Coils are the components of finished

transformers. They are made on automatic layer setting winding machines. A solid cylindrical former of predetermined diameter and length is being used as hase over which is made. Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as basic raw material. The coils are made in number of layers. The starting and finishing leads of each coil are terminated on either side of the coil. These leads are properly sleeved and locked at number of points. 2. Low Voltage Coils: L.V. Coils are also one of the components of transformer. The procedure of making low voltage coil is generally same as described earlier. The shape of the basic raw-material (Al or Cu) is rectangular. The Test: The "Turn Test" is carried out on the H.V. Coils as per the specifications.

Core Assembly

The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO) Silicon Steel
51

It is in the form of thin sheets & cut to size as per design. Generally three different shapes of core laminations are used in one assembly. Notching is performed to increase the magnetic path. The laminations are put through annealing process. These laminations are assembled in such a manner that there is no air gap between the joints of two consecutive sheets. The entire assembly is done on a frame commonly known as core channel. These frames being used as a clamping support of the core assembly. Core-Coil Assembly

The components produced in the coil winding and core assembly stages are then taken into core-coil assembly stage. The core assembly is vertically placed with the foot plate touching the ground. The top yoke of the core is removed. The limbs of the core are tightly wrapped with cotton tape and then varnished. Cylinder made out of insulating press board/ pressphan paper is wrapped on all the three limbs. Low Voltage Coil is placed on the insulated core limbs. Insulating block of specified thickness and number are placed both at the top and bottom of the L.V.Coil. Cylinder made out of corrugated paper or plain cylinder with oil ducts are provided over L.V.Coil. H.V. Coils are placed over the cylinder. Gap between each section of H.V. Coils including top & bottom clearances is maintained with the help of oil ducts, as per the design/drawings. The Top Yoke is refilled. Top core frame including core bolts and tie rods are fixed in position. Primary and secondary windings are connected as per the requirements. Phase barrier between H.V. phases are placed as per requirement. Connections to the tapping switch (if required) are made. Finally, the component is placed in the oven.

Drying: The complete assembly of core and winding is dried out completely and put into temperature controlled oven. This ensures that all
52

the moistures contents if present shall be remove resulting in elimination of any detrimental component. Tank-Up The core-coil assembly and tank supplied by the fabrication dept. are taken into tank-up stage. The procedure is: * The core-coil assembly is taken out of the oven and the "Megger test" is carried out. * Only if the megger value is as per the specification, the assembly may be taken for tank-up. * The tanks, supplied by fabrication dept. are brought to tank-up department duly painted. * Fittings like drain valves, HV & LV Bushings, conservator, oil level indicator and explosion vent are fitted in the tanks. * The Core-coil assembly is then placed into the tank and properly locked up. * Pure filtered transformer oil is filled in the tank to immerse the assembly only. * Connections of primary and secondary to the terminal bushings are made. Operating handle for ratio switch is fitted, wherever required.

Fig: (11.1) Tanking

Transformer Tanks All tanks are made of high quality steel and can withstand vaccum as specified by the international standards and the customer. All welds are tested, ensuring 100% leak proof of seems and mechanical strength. Transformer with Corrugated Fin-Type radiators can also be supplied.
53

The fins are manufactured of Gold-rolled steel. The fin height and length are according to customer's specifications And fins can be plain or embossed. All transformer tanks are given a smooth finishing by using the "SHOT BLASTING" process.

Fig: (11.2) Tank

Paint Process
Cleaning of Tanks * The cleaning of tank is done normally by chipping/grinding. * The outside surface of the tank is short blasted to achieve a very fine and smooth finish. Painting of Tanks * After cleaning the tanks, a coat of hot oil resistance paint is applied on the internal surface of the tank. * The outside surface is painted with a coat of Red Oxide primer and subsequently with one coat of enamel paint as per customer's requirement.

Fig: (11.3) Painting

Testing Process Each & every transformer undergoes routine tests, & following tests are carried out on finished transformers confirming to IS: 1180 & IS:

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2026 by qualified & experienced engineers with precision grade instruments.

The tests involved are following: * Measurement of insulation resistance. * Measurement of voltage ratio & check of voltage vector relationship. * Separate source voltage withstand test. * Induced over-voltage withstand tests * Measurement of No Load Loss & current. * Measurement of Impedance voltage/short circuit impedance & Load Loss. * Measurement of winding resistance. * Unbalance current. * Oil Dielectric test. * Temperature rise test. * Air pressure test. * Vaccum test. * Oil leakage test. Final assembly: All the parts like bushings, terminals, pipes, radiators, breather, vents, marshalling box, etc are been carefully fitted and checked before despatch.

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Fig: (11.4) Final assembly

Finishing & Dispatch * Fittings and accessories as per customer's specification and drawing are checked. * Air Pressure test is subjected to avoid any leakage and seepage on all transformer. * Transformers are filled with oil up to the minimum level marking, Wherever necessary. Loose accessories like, earthling terminals, bimetallic connectors; dial type thermometers are also checked for proper fittings.

Fig: (11.4) Transformer after Assembly

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Case study

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