ELETRA TRANSFORMERS TRAINING COURSE

Introduction
ELETRA transformers factory will be one of the biggest transformers manufacturing companies in the middle east . The factory is established to meet the increase in demand in power sector. It is the expected step to complete Alfanar electrical systems perfection . ELETRA manufactures a wide range of Three-Phase Distribution Transformers with oil immersed core type and Oil Natural, Air Natural cooling system (ONAN). The main characteristics of the ELETRA Transformers are: Rated power: From 50kVA to 10000kVA Rated voltage: Up to 36kV with two types of tanks: Free breathing with conservator Hermetically sealed The standard products items are listed as follow:

Transformer Range 1 2 3 4 5 6 7 300 KVA 500 KVA 1000 KVA 1250 KVA 1500 KVA 2000 KVA 3000 KVA

2- Transformer theory
Transformers are devices that transfer energy from one circuit to another by means of a common magnetic field. When an alternating current flows in a conductor , a magnetic field exists around the conductor If another conductor is placed in the field created by the first conductor such that the flux lines link the second conductor then a voltage is induced into the second conductor. The use of a magnetic field from one coil to induce a voltage into a second coil is the principle on which transformer theory and application is based. (Types, Applications, purpose ) ???

Type of Transformers

Distribution transformer 100-5000 KVA 11KV, KV,33KV/side cable box type

Kiosk type transformer

Corrugated tank type oil transformer 100-8000 KVA One Side cable box

Distribution transformer pad mounted Primary & secondary side cable box transformer with galvanized radiators 100-3000KVA

Dry type transformer 100-1000KVA

3-Design fundamentals
1- EMF equation
The relation ship between induced voltage and flux is given by the following equation E= 4.44* F *B* A *N E Induced EMF F frequency B flux density A core area N no. of turns

-turns ratio
E1/E = N1/N E1,E induced voltage for primary and secondary winding N1,N no of turns for primary and secondary winding

3-Amper turns balance

I1* N1 =I *N I1, I induced currents for primary and secondary winding

4- Technical data sheet

S.N.

1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 20 21 22 24 25 26

Transformer type Installation indoor or Outdoor Rated power (KVA ) Rated primary Voltage (KV) Number of taps and voltage % for Off Circuit regulation Rated secondary voltage at no load V Frequency (HZ) Number of phases Connection and voltage group Max Ambient temperature C Temperature rise top oil C Average winding Temperature rise C Altitude (max) .m SC- Impedance voltage % No Load losses (W) Load losses (W) Type of - Oil Parallel operation Standard Over all dimensions Width Depth Height (mm ) Oil Weight ( KG ) Total Weight (KG )

5-basic materials
The seven main materials in transformer categorized as follow A- Cooled rolled grain oriented silicon steel ( CRGO ) B-Copper conductors ( copper foil ,enameled copper wire , paper wrapped copper wire, Bus Bar, etc. C- solid insulating materials (Kraft paper , epoxy DDP, pressboard ,wood , etc..) D-Transformer oil E-steel (mild steel coils and sheet, stainless steel, U channel , tie rods , steel pipes ,etc) F- transformer accessories ( tap changer, bushings, oil temperature indicator , drain valve ,winding temperature Indicator , DGPT, Buchholz relay , dehydrating breather . Etc) G- painting materials )

6- Transformer construction
The core
The purpose of the core is to provide a low reluctance path for the magnetic flux linking primary and secondary windings. The magnetic circuit in a transformer is made of steel lamination sheets whose basic constituents are iron and approximately 3% silicon as an alloy element. Core laminations are compacted and clamped together using yoke clamps U channels and by tie-rods locking the top and bottom yoke clamps together.

Winding
The windings consist of the current-carrying conductors wound around the sections of the core. Copper is the primary material used as conductor because of high conductivity and mechanical strength. Conductors for low-voltage windings were originally made from foil copper sheet, and the conductor of high voltage winding were rectangle of round shape depend on the rating and voltage system of the transformer .

Active Part Assembly Process In the previous stage, the main part of the Active Part (core without the top leg and winding) is finished.The Active Part Assembly is as follows: 1. Insertion of the transformer windings into the iron core . Completion of the magnetic circuit by stacking the upper yokes 3. Insertion of axial wooden rod studs between iron core and internal diameter of windings for clamping the core and the coil to withstand the axial and radial forces during short circuit 4. The core assembly will be dried in a vacuum oven This step is necessary for removal of moisture from windings
Tank Manufacturing Process 1. First process in making tank is slitting of steel . this the slit is transferred to fin wall machine which forms the steel into corrugated wall 3. The next operation is spot welding to weld all four walls forming the tank . 4. Finally tanks are subjected to shot blasting & primer coating to produce tank in its final form Tanking Process 1. Transformer core assembly will be inserted into the tank . impregnated with oil by means of vacuum . Oil is supplied from the oil filtration plant 3. Finally ,top plate ,insulators & accessories are added to the final assembly after tanking takes place followed by final testing

7-tr
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8-testing of transformer
Transformer tests are classified into three categories Routine Tests, Type Tests and Special Tests as described below: Routine Tests Following tests are performed on every transformer in accordance with IEC 60076 standard: - Measurement of winding resistance - Measurement of voltage ratio and phase displacement check - Measurement of short-circuit impedance and load loss - Measurement of no-load loss and current - Dielectric routine tests (separate source AC voltage withstand test and short duration induced test) - Measurement of insulation resistance to earth of the windings.

over voltage withstand

Type Tests For transformers of new type or design, ELETRA carries out the following Type Tests on at least two units: -Temperature-rise test (in accordance with IEC 60076- ) -Dielectric type tests (Lightning impulse test in accordance with IEC 60076-3) Special Tests These tests are carried out after signing a contract with a client: -Measurement of zero-sequence impedance(s) on three-phase transformers -Short-circuit withstand test* (as per IEC 60076-5) -Determination of sound levels (as per IEC 60076-10) -Measurement of the harmonics of the no-load current

9-Information Required with Order

To fulfill a customers exact requirements, the following information along with orders requires : Transformer specifications Kind of transformer (For example: Separate winding transformer, auto transformer, etc.) Single or three-phase Connection symbol Frequency Type of oil (mineral or synthetic insulating liquid, and its class) Indoor or outdoor type Type of cooling Rated power Rated voltage Number of tapings; tapping range or tapping step (if tapping range is more than 5%, the voltage variation type and the location of the maximum current tapping) Highest voltage for equipment Insulation level for each winding Connection symbol Impedance voltage at rated current No-load losses Load losses at reference temperature For transformer with cable end box degree of protection according to IEC 605 Neutral terminals, if required for any winding Fittings required; and indication of the side on which meters, rating plates and oil-level indicators are to be fitted Accessories required Type of oil preservation system Temperature limits and atmospheric conditions