Categorizing

the transformer Transformer

production at GEMCO

Distribution Power

Core type Shell type

Straight cut Angular cut

ONAN(Oil natural Air natural)

Comparison between power & distribution transformer

Power
Transformer

Distribution
Transformer
 Comparison between power & distribution transformer
Power transformer Distribution
transformer
 Installation At substation At distribution and
(generation side). transmission
(consumer side).
 Connection Δ- Δ or Y- Δ, 3 wire. Δ-Y, 4wire.

 Capacity MVA. KVA.

 Voltage rating Usually stepped Usually stepped

down to 11kv. down from 11kv to
415v.
• Cooling system ONAF, OFAF,
ONWF, OFWF Usually ONAN.
Primary Distribution Transformer’s parts

Rod Gap Arrester

r
 Transformer type
Core type transformer

Winding

Core
 Comparison between core & shell type transformer

The advantages of each type are:

core-type (or three limbs) is the most commonly used method

of construction, the smaller core means less weight and expense.

shell-type (or five limbs) is used for larger transformers

because of a reduced height and better mechanical protection to
the winding because it is surrounded by core.

From a manufacturing standpoint, core-type & shell-type

designs are very similar.
Transformer Core type
 Comparison between core & shell type transformer

Angular Straight
Performance  Reduce reluctance against the  Provides more reluctance
magnetic flux by reducing the to magnetic flux due to
gaps between sheets. Hence more number of gaps. So
lessen the iron loss and performance is well below
betters the performance. angular.

Cost  Cost is more as huge amount  Cost is well below the

of core is wasted due to the angular cut.
cutting off at corner to make
it angular.

Preference  Preferred where efficiency is  Mostly used due to the

vital. less cost.
 Products / Services:

I ) Transformers:

Power Transformer, 3 Phase, 33/11KV, 1 MVA to 5 MVA

Distribution Transformer, 3 Phase, 33/0.415 KV, 100 KVA to 250 KVA
Distribution Transformer, 3 Phase, 11/0.415 KV, 50 KVA to 500 KVA
Distribution Transformer, 1 Phase, 6.35/0.24 KV, 5 KVA to 50 KVA
Distribution Transformer, 1 Phase, 11/0.24 KV, 15 KVA to 25 KVA

Apart from these, other rated transformer could manufactured as

per requirements of clients up to 5MVA

II)Repair & Miscellaneous Works:

Damaged Distribution & Power Transformers up to 20 MVA
 Process flow diagram
• Design product
PPM • Estimate cost

• Test raw materials

CPL • Report

• Electrical
Plant • Mechanical

• Test completed transformer

Testing • Report
Name of Raw Materials Specification of materials

CRGO Silicon Steel Sheet Grade M-5 (width 0.3mm, density-

7.65kg/dm3, Core loss 0.97-1.39 for 1.5-1.7T)
Copper Strips Electrolytic Copper of 99.9% purity

Super Enameled Copper SWG -14 to 21 Copper of 99.9%

Wire purity
Mild Steel Sheet Prime Quality

HT Insulator Electrical Porcelain Insulator

Transformer Oil As per IEC-296 Class-1

Insulated Paper & Board Electrical Grade 100%

Sulphate/Kraft Pulp
 Design specification
Raw material specification
 LT Coil dimension,
Thickness=5.6mm, width=11.2mm, insulation=.45mm,
density=61.92x10^-6 kg/m3
 HT coil type- SWG17 , supper enameled
dia-1.42-1.53, density= 8.9x10^-6 kg/m3
 CRGO Silicon Electrical Steel Sheet with thickness 0.3mm
&flux density Bm≤1.7Wb/m²
IEC Standard:
 76
Vector group:
 DYN-11
 Design specification
In design calculation
The design is usually 6 step core section with Cylindrical coils
 Summarizing the design:
•Specification of the transformer to be designed
•Chose Ez, Bm,
•Calculate Area and Diameter for core
•Find conductor size of HT & LT winding and calculate
current density
•Choose layout of windings-- numbers of turns per layer ,
numbers of layers, distance between coils
•Calculate R, X, Z.
•Calculation of performance
•Designing the tank
Transformer leg
Active Part

Tapping

Core

Insulation
Board

Insulation
Paper over
winding
 Testing
Each transformer undergoes following routine tests
as per IEC 60076 requirements:

•Di-electric strength test of transformer oil.

•Measurement of Insulation Resistance.
•High Voltage Test.
•Induced Over Voltage Test.
•Ratio Test.
•Vector Group Test.
•Measurement of No-Load Loss and Excitation Current.
•Measurement of Load-Loss and Impedance Voltage.
•Measurement of Winding Resistance.
•Temperature Rise Test.