Professional Documents
Culture Documents
SANJEEV KADIAN
Presents
TRAINING MODULE
INDEX
Particulars Pages
1. Understanding Transformers
2. Core
3. Conductor
4. Bushings
5. Buchholz Relay
8. Silicagel Breather
9. Sub-Assemblies
UNDERSTANDING TRANSFORMERS
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TRANSFORMER BASICS
INTRODUCTION
A transformer is basically an electromagnetic static equipment based on the principal of Faraday’s law of
electromagnetic induction. A transformer essentially consists of magnetic core, build-up of insulated silicon
steel laminations, upon which are wound sets of coils suitably located with respect to each other and
termed as 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 later case, it is known as step-down transformer. The primary winding is that
winding to which the supply voltage is applied, irrespective of whether it is higher or lower voltage winding,
the other winding to which the load is connected is termed as secondary winding.
If an alternating voltage is applied to the terminals of the primary winding of a transformer, with the
secondary winding open-circuited, a very small current will flow in the primary circuit only, which serves to
magnetise the core and to supply the iron loss of the transformer. Thus, an alternating magnetic flux is
established in the core which induces an e.m.f. in both primary and secondary windings. As primary and
secondary windings are wound on the same core and as the magnetic flux is common to both windings,
obviously, the voltage induced in the primary and secondary windings are, therefore, in direct proportion to
the number of turns in these windings.
LAMINATED CORE
TRANSFORMER LOSSES
Transformer loss mainly has two components: no-load loss & load loss.
No load loss results from steel materials, used for magnetizing core laminations. It includes hysteresis and
eddy current loss, dielectric loss and copper loss due to no-load current.
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Load loss arises from the resistive components, used for building the primary and secondary windings. It
comprises I2R loss of windings, loss due to eddy current and stray loss in the tank and core clamp.
Total
No-Load Load
EFFICIENCY
No-load loss of the transformer is constant and does not change with variation of load. However, load loss
changes in respect of the loading pattern. The transformer will yield maximum efficiency at a load when
no-load loss and load loss are equal.
REGULATION
The regulation of a transformer refers to the change of secondary terminal voltage between no load and
load conditions; it is usually quoted as a per cent or per unit value for full load at given power factor.
GENERAL CONSTRUCTION
Constructional Parts
The transformer is comparatively simple structure since there are no rotating parts, or bearings. The chief
elements of the construction are –
(1) Magnetic circuits, comprising limbs, yokes and clamping structures.
(2) Electric circuits, the primary and secondary windings, formers, insulation and bracing devices.
(3) Terminals, tappings and tapping switches, terminal insulators and leads.
(4) Tank, oil, cooling devices, conservators, dryers and ancillary apparatus.
1. Magnetic Circuit
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 are 0.18 mm, 0.23 mm,
0.30 mm and 0.35 mm. The two losses, due to varying flux, occur in the core: the eddy current and the
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hysteresis losses. The silicon content of the iron and the nature of annealing are very important in
determining the hysteresis loss. Silicon makes the material brittle, thus making it difficult to process.
Core Construction
The core built up with high-grade non-aging cold rolled grain oriented silicon steel lamination having high
permeability and low hysteresis loss. A three legged, mitered and interleaved type core construction is
adopted. Main limbs are bound fiberglass types and clamp plates to ensure adequate mechanical
strength, and to prevent vibration during operation rigidly bolt yokes. The clamping structure and core
sheet are specially connected not to make one turn circuit & connected to top of tank at one point.
Cooling of cores
In transformers of medium and high capacity with diameter of circumscribing circle D>=0.35m the cores
have the relatively small surface / volume ratio so that the temperature gradient in the core is excessive. In
such cases the cooling must be augmented by dividing the core in to different stacks with longitudinal oil
ducts (usually 6mm wide) running parallel to the lamination.
Core-Clamping
All core-clamping bolts shall be effectively insulated with enamel or preferably varnish impregnated but not
insulated with paper. The joints must be of inter leaved type. Liberal axial ducts must be provided so as to
ensure free circulation of oil and efficient cooling of the core, so that the maximum temperature at any
point will be within permissible limits.
Earthing
Positive earthing of the cabinet shall be ensured for providing two separate earthing pads. The earth wire
shall be terminated on to the earthing pad and secured by the use of star of self-etching washer. Using a
separate earth wire shall do earthing of hinged door.
Core Earthing
With the exception of individual laminations and core bolts, all internal metal parts of the transformer
require earthing.
2. Electric Circuits
The windings of a transformer are made of copper or aluminium wire and / or strip. Heavy current capacity
requires conductors of larger cross-section. To reduce eddy current losses within the conductors, several
small wires or parallel strips are preferable than to use one large strip. This gives rise to unequal
reactance components of the conductor, which can be reduced by transposing the conductors.
Two types of coil constructions are commonly used – Concentric or Pancake / interleaved. Between coils
segments, spacers are provided to permit dissipation of heat from the windings either by ventilation or by
a liquid cooling medium.
Double cotton, single cotton with an under layer of enamel or synthetics enamel, or double paper covering
are most commonly being used for winding wires. Strips are generally covered with layers of papers
known as DPC, TPC, QPC, MPC etc.
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Winding Constructions
The windings are arranged to ensure free circulation of oil and to reduce hot spots in the windings. All
materials used in the assembly of windings are insoluble, non-catalytic and chemically inactive in the hot
transformer oil. The windings are supported securely in axially as well as radially using radials spacers,
axial spacers, press board cylinders and clamp rings, so that they will not be displaced or deformed during
short circuits. The coils are clamped by adjustable pressures bolts at are top end and the face is uniformly
distributed to the windings using sturdy and to rings.
A transformer generally consists of LT & HT windings. The L.T. windings shall be circular and concentric
with HT windings on the outer side the electrical and magnetic balance under all conditions of operation.
The arrangement shall permit free circulation of the oil to ensure the absence of hot spots. It is essential
that the windings shall be subjected to through sinking occurring at site.
The general design and construction of the transformers and bracing’s of the windings shall be such that
no mechanical movements of the coils will be possible with dead short on either side of the transformer.
The short circuit ratings of the transformers shall be as per IS 2026 of latest issue. All clearance of
windings and other live parts shall be adequate for the maximum voltage operation plus 10 percent. There
should be sufficient clearance between H.V. and L.V. windings yoke and the coils and between coil in HT
windings to have free oil circulation. Current density in the high voltage and low voltage windings together
with the section of wire that will be used therein shall be clearly stated in the tender.
Insulation
The insulation material to be used for the windings shall be suitable for satisfactory service in tropical
climates in this country and full load operation as per ISS. DFC insulation shall be provided for high
voltage as well as low voltage windings.
The insulation between the H.V. and L.V. windings and core, comprises Bakelite – paper cylinder or
elephantine wrap that is typical. The insulation of conductors may be of paper, cotton or glass tape, glass
tape being used for air – insulated transformers.
Paper insulation usually necessitates the use of round coils, while the cross – over of the several strands
in a conductor must be properly shaped, and not merely twisted. The high voltage winding is separated
from the low – voltage winding by a series of ducts and Bakelite cylinders or barrels.
The connections to the windings are copper rods or bars, insulated wholly or in part, and taken to the bus
– bars directly in the case of air – cooled transformers, or to the insulator bushings on the tank top in the
case of oil – cooled transformers.
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Terminal Arrangement
a) Bushing terminals shall be provided with suitable terminal connectors of approved type & size for
cable/overhead conductors’ termination of HV side & cable termination on LT side.
b) The neutral terminals of 433V winding shall be brought out on a bushing along with the 433V volt phase
terminals to form 4 wires system for the 433V. Additional neutral bushing shall be provided for earthing.
4. Transformer Tank
All the tanks are of double welded construction and are reinforced by stiffener of structural steel. All
bottled connection to the tank is filled with the compressible oil tight gasket. The tank is provided with two
earthing terminals for the purpose of the grounding. The tank and accessories of the transformer can be
withstanding full vacuum of 0.1 Tore. And a maximum positive pressure of 1kg / sq.cm. In order to relive
the excessive gaseous pressure which may build up by a fault or an arcing inside the tank, it is equipped
with a pressure relief device / explosion vent which is designed to operate when the maximum gaseous
pressure in the tank exceeds 0.5 kg / 5q. cm.
Tank bodies for most of the transformer are made from rolled steel plates, which are fabricated to from the
container. While designing tanks for transformer, a large number of factors include keeping the weight,
stray load losses and cost a minimum.
The tanks should be strong enough to withstand stresses produced by jacking and lifting. The size of the
tank must be large enough to accommodate cores, windings, internal connections and also must give the
require clearance between the windings and the walls.
The fittings include thermometer pockets, drain cock, rollers or wheels for moving the transformer in to
position, eye – bolts, for lifting, conservators and breaths. Cooling tubes are welded in, but separate
radiators are individually welded and afterwards bolted on.
Radiators
During service, the tank body can dissipate a total loss equivalent to 500 W/Sq m (maximum) of the tank
surface area. In case the total loss, i.e. (no-load + load loss) is more than the loss dissipated by tank
surface, the loss in excess is required to be dissipated with the help of additional cooling surface which is
commonly called radiator.
Classification of radiators
Elliptical tube radiators and pressed steel radiators operate on then convection process of cooling,
whereas a corrugated wall panel performs cooling by radiation only.
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Corrugated wall panel radiators are commonly being used for sealed type transformers and also on such
places where there are restrictions on overall dimensions. The radiators are widely used for transformers
built for export, as corrugated wall panel transformers occupy less space and can accommodate more
transformers in one container during transport.
Cooling Methods
A Simple cooling
1 AN Natural cooling by atmospheric circulation, without any special devices. The
transformer cores and coils are open all round to the air. This method is confined
to very small units of a few KV, at low voltages.
2 AB In this case the cooling is improved by an air blast, directed by suitable trunking
and produced by a fan.
3 ON The great majority of transformers are oil – immersed with natural cooling, i.e. the
heat developed in the cores and coils is passed to the oil and thence to the tank
walls, from which it is dissipated. The advantages over air cooling include freedom
from the possibility of dust clogging the cooling ducts, or of moisture affecting the
insulation, and the design for higher voltages is greatly improved.
4 OB In this method the cooling of an ON – type transformers is improved by air blast
over the outside of the tank.
5 OFN The oil is circulated by pump to natural air – cooler.
6 OFB For large transformer artificial cooling may be used. The refrigerator, where it is
cooled by air – blast.
7 OW An oil – immersed transformer of this type is cooled by the circulation of water in
cooling tubes is situated at the top of the tank but below oil – level.
8 OFW Similar, to OFB, except that the refrigerator employs water instead of air blast for
cooling the oil, which is circulated by pump from the transformer to the cooler.
b. Mixed cooling
ON/OFN, ON/OFB, ON/OFW, ON/OB/OFB, ON/OW/OFW, ONAN, ONAF, OFAF
Cooling ducts
In large transformers, the cooling surface of the cores must be augmented otherwise temperature rise will
be excessive owing to small surface/volume ratio of the cores. Cooling ducts provides the additional
surface. The cooling may be (I) horizontal or (ii) vertical. The vertical cooling ducts are along the direction
of laminations and hence can be easily provided. The horizontal ducts are across the laminations and
therefore require special punching of core. The oil following through these ducts takes away the heat.
Paintings
Tanks should be sand blasted or cleaned by chemical process before painting. In general a primary coat
of suitable anticorrosive paints followed by two coats of standard grey is applied on the tanks and
radiators.
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SCHEDULE OF TESTS
ROUTINE TESTS
TYPE TESTS
Following tests are conducted on only one transformer of each rating for a particular design,
subject to client’s requirement.
FINAL TEST
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TESTING PROCEDURE
INSULATION RESISTANCE:
The Oil/Air Temperature is measured and recorded immediately prior to the test. The insulation resistance of each
windings corresponding to other windings and to earth is measured and recorded.
I.R Value between :
HV & E : Connect Positive terminal of Insulation Tester to HV Bushing and Negative
Terminal to the Earth.
LV & E : Connect Positive terminal of Insulation Tester to LV Bushing and Negative
Terminal to the Earth.
HV & LV: Connect Positive terminal of Insulation Tester to HV Bushing and Negative to
LVBushing.
V1 N1
Voltage Ratio = ------ = -------- where, N1 = Primary Turn
V2 N2 N2 = Secondary Turn
Transformer’s A-phase of primary side and A-phase of secondary side are shorted, and in primary side 3-
Phase supply (About balance voltage 400 Volts) applied at rated frequency. Voltage is , then, measured
on following points :-
IV-2V =
IV-2w =
1W-2W and !W-2V
In this test IV-2W and IV-2V may be same and 1W-2V may be more than 1W-2W
In this test the full test voltage given below applied for 60 seconds between the winding under test and all terminals
of remaining windings, core, frame and tank of the transformer connected together to earth.
TESTS :
(A) High Voltage Test - In this test secondary side of the transformer and tank are earthed and from primary side
full test Single Phase voltage applied for 60 seconds at rated (50 Hz) frequency.
(B) Low Voltage Test - In this test primary side of the transformer and tank are earthed and from secondary side
full test, Single phase voltage applied for 60 seconds at rated (50 Hz) frequency.
The transformer can be tested on either LV or HV side. Double the rated voltage at double the frequency is applied
at the testing side. The other side is open circuited.
Duration of Test : 60 seconds
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The test is conducted by a Three Wattmeter Method. The No Load Loss and the no load current are measured at
rated frequency at a rated voltage while the other winding is to be left open circuited. In this way after applying
rated 3 Phase voltage at rated frequency from LV side, the current is measured in Ammeter. This current will be no
load current or magnetizing current, and the total reading of the watt meters will be the Total No Load Loss of the
tested transformer.
To measure the No Load Loss and No Load current of Power Transformer one CT-PT set is connected to an Auto
Transformer.
The Impedance voltage/short circuit impedance and load loss are measured at rated frequency by applying an
approximately full load current to one winding with the other winding short circuited. The measurements may be
made at any current between 25 percent and 100 percent, but preferably not less than 50 percent of the rated
current (principal tapping) or tapping current to the test current.
The measured value of Load Loss may be corrected by the following formula :
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Rated Current
Total Loss = --------------------
Test Current
The measured value of the impedance voltage may be corrected by the following formula :
Rated Current
Total Impedance voltage = --------------------
Test Current
To measure the resistance of LV and HV Winding , Kelvin and Wheatstone Bridge are respectively used. The
resistance and temperature of each winding are recorded.
UNBALANCE CURRENT:
In this test of the Transformer, all three phases of secondary (Star Connected) are shorted and shorted point linked
to the neutral point of transformer with an Ammeter.Then, full load current at rated frequency is applied to primary
(Delta Connected) of the transformer. The current measured between the shorted secondary and the neutral point is
the unbalance current. Circuit diagram is respectively same as load loss test :-
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In this test LV winding of the transformer is shorted and from HV winding full losses (Load loss at 75 Deg. Cent. +
No Load Loss) is fed. One thermometer is placed in oil filled thermometer pocket of transformer for oil temp. and
other 3 Nos. thermometers in different directions of the transformer for ambient temp. After feeding the total loss at
transformer, the voltage current, top oil temp. and ambient temp. is measured. These all readings are taken one by
one after every hour. This process is continued till oil temperature rise of transformer remains constant. Keeping oil
temp. rise constant, load is reduced at full rated current for one hour, after one hour supply shut-off. After shutting
off the supply hot resistances of winding are immediately measured. Thus, after plotting the graph between time
and hot resistance, we can find out the highest actual hot resistance at the zero time. In this way the maximum
winding temperature rise can be calculated by the following formula :
To test the Dielectric strength of oil, a motorised oil testing set is used . Before using this instrument, the oil pot of
this instrument washed with the same oil, which to be tested. After washing the pot, the gap between the electrodes
is set at 2.5 mm and the oil is filled in it. Wait for about 10 minutes, so that the air bubbles disappear. After this, the
instrument is switched ‘ON’ and the flash point (in KV) is noted. This process is repeated for six times and the
average of the six values is the Dielectric Strength of the oil.
This is a type test which is conducted on the transformer tank. The tank may be fixed with a dummy cover with all
fittings including bushings in position and subjected to a pressure of
0.35 Kg/Cm2 (Hg) upto 1000 KVA Transformer Tank
0.80 Kg/Cm2 (Hg) above 1000 KVA Transformer Tank
created inside the tank and maintained for one hour. The permanent deflection of flat plate, after pressure has been
released should not exceed the values given below:
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VACUUM TEST:
This is a type test , which is conducted on transformer tank. The transformer tank may be completed with all fittings
including bushings in position and shall be subjected to full vacuum corresponding to (-) 0.7 Kg/Cm.sq.(Hg) created
inside the tank for one hour. The permanent deflection of flat plates after the vacuum has been released shall not
exceed the value specified below without affecting the performance of the transformer.
This is a type test, which is conducted on fully completed transformer. The transformer shall be oil filled and
complete with all fittings. Then following air pressure is applied:
1) 0.35 Kg/Cm2 (Hg) pressure – For transformers upto 1000 KVA for one hour
2) 0.80 Kg/Cm2 (Hg) pressure – For transformers above 1000 KVA for 12 hours
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The following is the list of the major raw-material required for the manufacture and repair of transformers.
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CORE
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CORE
The need for electrical steel sheets of highest quality has increased in recent years
due to rapid development of electrical machinery industry in many countries. Grain
Oriented steel sheets namely ORIENTCORE, ORIENTCORE H1-B & ORIENTCORE
HI-B.LS are some of the finest quality of core.
ORIENT.HI-B.LS is a novel type with marked lower core losses, produced by laser
irradiation of the surface of ORIENTCORE.HI-B sheets.
Quality
Standard Sizes
ORIENT.HI-B ORIENT.HI-B.LS
Coils Thickness 0.23mm & 0.27mm 0.23mm,0.27mm
0.30mm & 0.35mm
Standard Width 914 mm & 950 mm
Available Width From 50mm to 1000 mm From 50mm to 950 mm
Though ORIENTCORE and ORIENTCORE.HI-B are grain orient steel sheets with
excellent magnetic properties, mechanical stress during such operations as cutting,
punching and bending affect their magnetic properties adversely. When these stress
are excessive, stress relief annealing is necessary.
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Available Grades
ORIENTCORE
o M1, M2, M3, M4, M5 & M6
ORIENTCORE.HI-B
o 23ZH90, 23ZH95, 27ZH95,27ZH100,30ZH100
o M-0H,M-1H,M-2H,M-3H
ORIENTCORE.HI-B.LS
o 23ZDKH90,27ZDKH95
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Conductor
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CONDUCTOR
Conductors are one of the principal materials used in manufacturing of transformers.
Best quality of copper rods are procured from indigenous as well as foreign sources.
Normally 8 mm & 11 mm rods are procured. For each supply of input, test certificate
from suppliers is obtained and at times, such input is got tested from reputed test labs.
After the wires & strips are drawn as per clients requirements they are moved on to
paper covering process. To prevent the inclusion of copper dust or other extraneous
matter under paper covering the conductor is fully cleaned by felt pads or other suitable
means before entering the paper covering machine. As per the customers
requirements DPC, TPC & MPC conductors are produced. It is ensured that each layer
of paper is continuous, firmly applied and substantially free from creases. No bonding
or adhesive material is used except to anchor the ends of paper. Any such bonding
materials used to anchor the ends do not have deleterious effect on transformer oil,
insulating paper or the electric strength of the covering. It is ensured that the
overlapping percentage is not less than 25% of the paper width.
Arrangement of layers
According to the number of layers used the paper is applied as follows.
Two layers:-
Where there are two layers both of them are wound in opposite directions.
Grade of paper
The paper, before application, is ensured to be free from metallic and other injurious
inclusions and have no deleterious effect on insulating oil. The thickness of paper
used is between 0.025 mm to 0.075 mm.
Enameled Conductor
Apart from paper covered conductors, we have all the facilities of producing enameled
conductors as per customer specified requirements.
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BUSHINGS
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BUSHINGS
Insulators and Bushings are built with the best quality Porcelain shells manufactured by
wet process. The materials that go into the manufacture of these insulators offer best
quality mechanical and electrical characteristics. The standard colour of the glaze is
brown, but white glazed insulators can also be made available on request.
Manufacturing process
For manufacture of electro porcelain, high quality indigenous raw materials viz, China
Clay, Ball Clay, Quartz and Feldspar is used. The raw materials in lots undergo
thorough test in quality control laboratory before being user for manufacture.
Quartz and feldspar are ground to required finesses and then intimately mixed with ball
and china clay in high speed blungers. They are then passed through electromagnetic
separators, which remove iron and other magnetic impurities. The slip produced is
passed to a filter press where extra water is removed under pressure and the resulting
clay cakes are aged over a period. The aged cakes are extruded to required form viz.,
cylinders, on high vacuum de-airing pug mill. The extruded blanks or cylinders are
given shapes of Insulators / Bushings which are conditioned and are shaped on
copying lathes as the case may be.
These shaped insulators / bushings are then dried under controlled conditioned and
then they are glazed, Trade mark, month, year and country of manufacture are marked
before firing. The glazed shells are fired in fuel efficient kilns having temperature
controls to ensure uniformity of firing high strength in porcelain shells. Metal parts used
in the assembly of Insulators, are of blackheart and malleable cast iron and are hot dip
galvanized to conform to international standards.
All insulators & bushings undergo routine electrical and mechanical tests. The tests
before and after assembly are carried out according to IS Specifications, to ensure
their suitability for actual conditions of use. Porosity tests are also carried out regularly
on samples from every batch, to ensure that the insulators are completely vitrified.
These insulators are then visually checked and sorted, before they are packed in sea
worthy packing, to withstand transit conditions.
Bushing Insulators
o Hollow Porcelain Bushings upto 33 KV
o Application : Transformers, Capacitors, Circuit Breakers etc.
Pin Insulators
o Pin Insulators conforming to ISS, B.S., IEC and other international
standards upto 33 KV
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Product Specification
1. H.V. Bushings (IS:3347) 1. 12-17.5 KV / 250 amps
2. 12-17.5 KV / 630 amps
3. 12-17.5 KV / 1000 amps
4. 12-17.5 KV / 2000-3150 amps
5. 24 KV / 250 amps
6. 24 KV / 630 amps
7. 24 KV / 1000 amps
8. 24 KV / 2000 – 3150 amps
9. 36 KV / 250 amps
10. 36 KV / 630 amps
11. 36 KV / 1000 amps
12. 36 KV / 2000-3150 amps
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EPOXY BUSHINGS
All Epoxy Resin Cast Components are made from hot setting reins cured with
anhydrides; hence these provide class-F Insulation to the system. In an oxidizing
atmosphere, certain amine cured Epoxy Resins can start to degrade at 150ºC whereas
the anhydride cured systems are stable at 200ºC therefore our epoxy components are
cured with anhydrides which gives them a longer life.
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Buchholz Relay
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BUCHHOLZ RELAY
Power transformers are considered to be highly reliable type equipment, yet, in order to
ensure the continuity of service that modern conditions demand, protective devices are
required. The purpose of such devices is to disconnect faulty apparatus before large
scale damage caused by a fault to the apparatus or to other connected apparatus.
Such devices generally respond to a change in the current or pressure arising from the
faults and are used for either signaling or tripping the circuits.
Protective devices in the ideal case must be sensitive to all faults, simple in operation,
robust for services and economically feasible. Considering liquid immersed
transformer, a near ideal protective device is available in the form of gas and oil
operated relay described here. The relay operates on the well known fact that almost
every type of electric fault in a liquid immersed transformer gives rise to a gas. This gas
is collected in the body of the relay and is used in some way or the other to cause the
alarm or the tripping circuit to operate.
The principle of the gas and oil relay was first successfully demonstrated and utilized
by “Buchholz” many years back.
Applications
Double element relays can be used in detecting minor and major faults in a
transformer. The alarm element will operate, after a specified volume of gas has
collected to give an alarm indication. Examples of incipient faults are.
The alarm element will also operate in the event of oil leakage, or if air gets into the oil
system. The trip element will be operated by an oil surge in the event of more serious
faults such as
1) Earth faults
2) Winding short circuit
3) Puncture of bushings
4) Short circuit between phases
The trip element will also be operated if a rapid loss of oil occurs.
Available range
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Pipe bore in mm 25 25 50 80
Transformer rating ≤ 1.6 ≤ 5.0 > 5.0 > 10.0
In MVA ≤ 10.0
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a) Welded Lid
b) Bolted Lid
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a. Gear assembly
b. Magnetic couple
c. Float with arm
d. Cam assembly with mercury switch
e. Dial and pointer.
The float is hinged and swings up or down when oil level rises or falls. This rise or fall
rotates the bevel gear and thus the pinion of the gear assembly. The pinion on turn
rotates the driving magnet inside the conservator. The follower magnet positioned
outside carries a pointer and a cam. The pointer reads oil level and the cam is set to
operate the mercury switch at a predetermined low level.
One normally open mercury switch is provided to actuate low level alarm. The switch is
adjustable to compensate error in orientation of pad. Leads of this switch are
connected to the terminals.
Specifications
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SILICAGEL BREATHERS
Breathing Process
Breathing is the process wherein Transformer sucks the air inside or pushes the air
outside its body. When Transformer is loaded or unloaded, the oil temperature inside
the transformer tank rises or falls. Accordingly, the air volume inside the tank changes
by either sucking in or pushing out the air. This phenomenon is called “Breathing” of
the transformer.
Now, the air which is being sucked in contains either foreign impurities and / or
humidity which changes dielectric strength of oil. For proper working of Transformer, it
is absolutely necessary that dielectric strength of transformer oil remains unimpaired.
Hence, it is necessary that air entering into the transformer is free from moisture &
foreign impurities.
The breather is made out from Aluminium (Gravity) die cast in two parts i.e. Top shell &
bottom shell and a gel compartment is made out from Tin plate which is known as
removable inner container. The inner gel container can be withdrawn by unscrewing
the wing-nuts removing the top shell or bottom shell portion of the breather in case of
two piece model.
A sight windows have been provided to observe / inspect the condition of Slicagel &
Oil level.
An oil seal made out of aluminium sheet is fitted in the base of the breather to prevent
diffusion of moisture into silicagel when no breathing is taking place.
The entire oil cup is also transparent. Hence, change in the level of oil as well as any
sedimentation in oil is clearly visible as against invisibility in window type
Available range
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Above table is just a guide line. The gel content or the size of the breather is
determined by the volume of air passing through the breather, the oil contents of the
transformer and the atmospheric conditions at the place of installation. Hence the
ultimate user should decide the size and gel content of the breather that would suit to
him.
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Sub-Assemblies
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SUB ASSEMBLIES
HV & LV Coils
Core Assembly
Core-Coil Assembly
Pressed Steel Radiators & Panels
MS Tanks Corrugated & Radiator type
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COILS
Coils are of two type
a) High Voltage Coils
b) Low Voltage Coils.
CORE ASSEMBLY
1. Core is one of the components of finished transformer. Core assembly is
done manually.
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2. The basic raw-material is Cold Rolled Grain Oriented Silicon Steel and 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.
3. These laminations are assembled in such a manner that there is no air gap
between the joints of two consecutive sheets.
1. The Core assembly is vertically placed with the foot plate touching the
ground. The top yoke of the core is removed and is kept in a safe place. The
limbs of the core are tightly wrapped with cotton tape and then varnished.
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Insulating block of specified thickness and number are placed both at the top
and bottom of L.V. Coil.
3. Cylinder made out of corrugated paper or plain cylinder with oil ducts are
provided over LV Coil. HV Coils are placed over the cylinder. Gap between
each section of HV coils including top and bottom clearances is maintained with
the help of oil ducts; as per the design/drawings.
4. The Top Yoke is refilled. Top core frame including core bolts and tie rods are
fixed in position.
TANKS
Best quality MS Sheets, Press Steel Radiators and Corrugated Panels are procured
from indigenous and foreign sources. These radiators and panels are welded with the
tanks fabricated in-house. In case of Power Transformers Radiators provided are of
detachable form due to large in size and ease of shipment.
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Tap Changer
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OLTC
On Load tapchangers marketed by us are tested as per IS 8468-1977 Amendment 1-1980. On
Load Tapchanger (OLTC) are also suitable for off circuit furnace duty application. It comprising
of driving mechanism and high speed selector switch. Optional equipments include Remote
Tapchanger Control Cubicle (RTCC) with indicating apparatus, fitted with devices to prevent
malfunctioning. Designed for unidirectional power flow but can be used for bidirectional power
flow under certain combinations of current rating and step voltage.
The tap changer is designed for operation at current upto 300 amperes. The Selector Switch
which is capable of making and breaking load current in addition to selecting tapping, is
housed in an oil filled container and separated from the transformer oil by an oil-tight cast
epoxy resin Terminal Board.
At one end of the container a separate chamber houses the motor and driving mechanism. A
weather proof door provides access to the operating mechanism and a suitably positioned
window allows easy reading of the tap position indicator.
Available Range
Construction
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Tap changing is done by rotating an insulating driving shaft. Bridgings are made between two
terminal stud contacts either by snap action of self centering spring loaded ring or by sliding
palm fixed with centre drive shaft. The centre shaft is operated by means of an externally
mounted hand wheel on a double sealed stuffing box having spring loaded positioner with tap
position indicator. Indicator mechanically shows the tap number of which the tap changer is
operating. Provision is made for pad locking in any tap position. Between first and last position
stoppers are provided to avoid bridiging across range.
Material of construction
Available Range
KV AMPS POSITION TYPE HANDLE
11 30 5 SB T
30 7 SB T
30 9 TR T
30 11 TR W
60 5 SB T
60 7 SB T
60 9 SB T
60 5 TR W
60 7 TR W
60 9 TR W
60 11 TR W
100 5 SB W
100 7 SB W
100 5 TR W
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22 30 5 SB T
30 7 SB T
30 5 TR T
30 7 TR T
30 9 TR T
60 5 SB T
60 7 SB T
60 5 TR W
60 7 TR W
60 9 TR W
100 5 TR W
100 7 TR W
100 9 TR W
150 5 TR W
150 7 TR W
150 9 TR W
250 5 TR W
250 7 TR W
250 9 TR W
22/11 30 5 SB T
30 7 SB T
30 5 TR W
30 7 TR W
30 9 TR W
60 5 SB T
60 7 SB T
60 7 TR W
60 7 TR W
60 9 TR W
100 5 TR W
100 7 TR W
33/11 30 7 TR W
33 30 5 TR T
30 7 TR T
30 9 TR T
60 5 TR W
60 7 TR W
60 9 TR W
60 11 TR W
100 5 TR W
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Temperature Indicator
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SPECIFICATIONS
1. Dial 140 mm diameter with 270º part circular scale
marked boldly for rapid reading.
2. Standard Ranges 0-120ºC, 20-240ºC, 30-150ºC, 0-150ºC
3. Accuracy of indication ±1.0% f.s.d
4. Control Switches Upto 4 numbers, electrically isolated normally
open S.P.S.T. dry electrode mercury and glass
switches.
5. Switch Rating 5 Amps continuous at 250 Volts A.C. or D.C.
overload rating of 10 Amps in A.C. circuit only
for short duration such as motor starting.
Switches are independently adjustable for
making and breaking contacts at pre-set
temperatures.
6. Capillary Standard Lengths 5m, 6m, 10m and 12m
stainless steel armour sheathed
7. Bulb Type F or Type M
8. Case Finish Stove enameled hammerstone deep blue
outside and all white inside.
9. Case Mounting Projection mounting with back straps. Weather
proof case (protective class IP 55 of IEC 529) is
suitable for outdoor service. However a canopy
type weather shield will improve visibility under
tropical conditions.
10. Capillary Entry Bottom or Top of case – vertical
11. Electrical Entry Bottom of case – vertical through 2 holes (19
mm or 26 mm)
12. Maximum Pointer Resettable from outside by means of a
screwdriver is fitted to the instrument window. A
special damping device ensures accuracy of
readings even under vibration conditions.
13. Switch Testing A switch testing knob is fitted on the instrument
lid to facilitate checking of the switch settings
from outside, without removing the instrument
lid.
14. Electrical Connection Are made to the terminal blocks inside the
instrument case. Approved insulating materials
are used and all circuits to ground tested at
2500 Volts A.C. 50 Hz for 60 seconds. A wiring
diagram is fixed inside the instrument case.
Temperature Indicators with dials of 60º segmental scale & 240º part circular scale is
also available.
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Transformer Oil
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TRANSFORMER OIL
Transformer oil is a petroleum base mineral oil used extensively in power and
distribution electrical equipments such as transformers, switchgears, capacitors and
allied equipments. It provides insulation between windings, winding to core, winding to
tank and acts as a coolant to take away the heat generated by power losses and also
acts as an arc quenching medium.
Quality
Quality of transformer oil marketed by us has to undergo tests and checks conforming
to IS-335 of BIS (Bureau of Indian Standards) and also international standards:
Oxidation stability, gas absorption, chemical deterioration, break down voltage,
resistivity, dielectric dissipation factor etc. Physical characteristics tests are also
conducted in a routine manner. We offer following distinct advantages:-
4. Low Viscosity
Improves cooling
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Technical Characteristics
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Note : At the time of receiving the damaged transformer the repair firm's
representative must ensure that the state of transformer is clearly indicated on the
receipt slip i.e., all the missing and damaged items must be clearly mentioned.
2. Lifting:
5. Joint inspection:
All observations made must be recorded on a pre-formatted table in the
inspection report.
(format enclosed)
ii) If sealed, the seals are broken in the presence of the inspector.
iv) Check transformer tank for leakages / damages, especially the radiator fins /
tubes. Check if there are any parts missing. Also check the pressure relief
valve.
v) Transformer Oil
Check the dielectric strength of the oil drained from the transformer tank.
Make note of its colour and any adour arising from it. Also check for any
foreign material.
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vi) Check the condition of bushings i.e., whether cracked or broken. Remove
them. Note their specification.
x) Metallic Pieces
Check if there are any metallic pieces on the yoke or else where.
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xiii) Check if the inter coil connections, delta connections and its neutral
connections are loose, broken or burnt. Check whether the windings appear
burnt.
xiv) Remove the yoke. Take out the windings and if necessary re-perform the
continuity test to positively identify the fault. (If in the windings)
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Check the condition of the core whether it is pitted, scratched, melted, has
any hot spots, and has any foreign material deposits. The diameter, cross-
sectional Area, window height and limb size of the core must be recorded.
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v) Approval of Estimate
The next phase is to be taken up only upon receipt of approved estimate /
work order placed by the client for repair of specific damaged transformers.
If, for any reason, the client disapproves the estimate then the cost of to and
fro transport of the transformer must be realised from the client.
vi) Design
If the repair work is found cost effective and the repair work entails major
overhauling then electrical design is made by the design engineers keeping
in mind the required C.D, core diameters, core cross-sectional area, window
height, limb size, total copper weight, maximum flux density, rating, vector
group, voltage class, no load losses and the load losses.
The purchase manager procures the material and places it with the store.
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The store on receipt of the material invites the QC manager to inspect the
same. Only subsequent to the QC manager's approval can the store accept
and issue the material.
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ix) Requisition of material
3) Insulation
The insulation cutting department is
responsible for cutting and providing
the insulation material required by
various departments. This is done as
per work orders issued to them.
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5) Core-Coil Assembly
The coil assembly department with
inputs from the winding, insulation
cuttings and the core assembly
department assembles the windings
on the core, placing the requisite
insulation material at the specified
places. It also makes the necessary
delta, neutral and inter coil
connections. It brings out terminal
leads and solders / brazes the
connection lugs on them. It also
assembles and connects the tap
changers. This all is done as per the
work orders issued to them.
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6) Drying of Transformer
The core-coil assembly in the drying
oven are periodically checked for
insulation resistance values with a
suitable megger by personnel of the
tank-up department. Only when the
stipulated megger values (about 1500
Mohms) have been attained do the
tank up people take these assemblies
out for tanking up.
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9) Tank-up
The tank-up department mounts the
transformers into the cleaned and
painted tanks as per work orders
issued to them. The transformer tank
is topped up with oil of dielectric
strength of breakdown value 60 KV at
2.5 mm electrode gap. The
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2. Final Inspection
The client's representative shall
examine and conduct tests on the
transformers to satisfy himself of their
worthiness. If any minor anomalies
are noticed, they are put right. The
final inspection report is prepared
and counter signed by both the
client's representative and the firm's
representative. (normally the testing
engineer)
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4. Invoicing
As per the approved estimate the
invoice for repairs carried out is duly
prepared including applicable taxes
and duties and presented to the client
for realisation.
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2. Insulation
a) Kraft Paper
b) Pressboard
c) Pre-compressed Pressboard
d) Cotton Tape
e) Empire Sleeve
f) Glass Sleeve
g) Bakelite Flat
h) SRBP Tube
i) Permali Wood
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j) Haldi Wood
k) Press Paper
l) Crepe Paper
m) Webbing Tape
3. Transformer Oil
5. Adhesives
a) Synthetic Gum
b) PVA Emulsion
6. Connection Lugs
7. Solder Wire
a) Sn:Pb=70:30
b) Sn:Pb=60:40
8. Brazing Rod
9. Welding Electrode
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15. Borax
22. Valves
a) Wheel Valve
b) Flange Valve
23. Radiators
a) Elliptical Tube
b) Pressed Steel
c) Corrugated Panel
e) EC Thinner
29. Lock
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WINDING DEPARTMENT:
HT Winding Machine
Motorised 3 H.P. 3 Phase “V” Belt Drive with Automatic Layer Setter, Mechanical
Clutches & Turn counter, Spool Stand with brakes. Foot speed control.
LT Winding Machine
Motorised 3 H.P. 3 Phase “V” Belt Drive with Mechanical Clutches & Turn counter,
Spool Stand & Foot speed control.
TURN COUNTER
Direct digital display of number of turns, complete with detachable “Yoke Assembly”
and sunmica working table. Range: 0-2200 Turns
Accuracy: ±0.1%, ±1 Turn
Power : 230 V. AC + 10%, 50 Hz.
COIL ASSEMBLY DEPARTMENT :
Gas Welding Set
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INSULATION DEPARTMENT :
4' Power Sharing Machine
Portable Jigsaw
Motorised, single phase power input 580 W.
Hand Operated Small Circle Cutting Machine
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Vices - Size 3
Size 2
M.S. Forged Body, Slid Hand Operated.
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MATERIAL HANDLING :
TANK UP DEPARTMENT :
Vacuum Pump
1 HP, 3 Phase, 415 Volt. Capacity 650 mm of Hg.
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OTHERS :
GENERATORS :
Capacity 30 KVA
Capacity 10 KVA
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7. PLIER 8” 6 Nos.
15. 4” 2 Nos.
RIGHT ANGLE 6" 2 Nos.
(Tri square)
12” 2 Nos.
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a) KELVIN BRIDE
Measuring Range - 0.2 micro ohm to 11 ohm Accuracy ±0.05% micro or ±1 slide wire
divn, which is greater rated current: Upto10 Amp. D.C. with light spot Galvanometer
D.C. Power source of 6 V. 10 Amp. OVERALL DIMENSION: Length 430 mm, width 280
mm, height 165 mm, galvanometer Length 280 mm, width 180 mm, Height 140 mm
a) VOLTMETER
Measuring Range - 0-150/300/600 V. Accuracy ±0.5% Portable Precision grade Moving
Iron Low Powerfactor (0.2) A.C. Voltmeter in wooden case provided with Knife edge
pointer antiparallex mirror scale.
b) AMMETER
Measuring Range 0-1/5 Amp. Accuracy ±0.5% Portable Precision Moving Iron Low
power factor (0.2) A.C. Ammeter in wooden case provided with knife edge pointer
antiparallex mirror scale
c) WATTMETER
Portable low power factor low wattage analogue wattmeter (0.2 L.P.F) single phase
moving coil built in transducer in wooden case provided with knife edge pointer
antiparallex mirror scale.
Current coil 2.5/5A Potential Coil - 600 V
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d) CURRENT TRANSFORMER
Ratio: 10-15-30-50-100/5A Rated Burden 15 VA
Accuracy Class 0.2 Frequency 50 C/s
Voltage Class 660 V Effectively earthed system
Portable current Transformer in Teak Wood case
e) DIMMERSTAT (VARIAC)
Continuously variable voltage auto transformer indoor oil cooled construction,
motorised with single phase supply portable type suitable to work on 3 phase 50 C/s
A.C. Supply with base channel & four wheels. Input: 415 Volts, 3 Phase, 50 C/s A.C
Output: 0-470 Volts, 3 Phase, 50 C/s A.C
Capacity: 200 Amp.
f) AUTO TRANSFORMER
Capacity: 200 KVA, 3 Phase oil cooled and having 2 Nos. Taps of 800 & 1200 Volts,
input voltage 400 Volts with base channel & four wheels
g) POWER CAPACITORS
Capacity : 100 KVAR Rated Voltage : 440 V. AC
50 C/s, 3 Phase with internal delta connection
h)
FREQUENCY METER
Range 0-70 Hz.
i)
STEP-UP TRANSFORMER
Capacity 100 KVA, Ratio 220 / 3000 volts with 2 Nos. tapping (150 & 300) in HV Side
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protect the unit 2.4 mm/2.5 mm “GO” “NO GO” gauge for gap adjusting, Table mounting
type with fibre glass tank for H.V. Transformer and metallic box for control panel.
a) Stop Watch
c) VOLTMETER
Moving Iron A.C. Voltmeter of 1.5 class
Accuracy Measuring Range 0 - 1200 V.
d) AMMETER
Moving Iron A.C. Ammeter of ±1.5 Class
Accuracy, Measuring Range 0-80 A.
e) FREQUENCY METER
Accuracy class: 1.0 Measuring Range: 0-150 Hz.
f) DIMMERSTAT (VARIAC)
Capacity 28 A, 3 Phase 50 Hz. 0-470 V, output
g) STEP-UP TRANSFORMER
Range : 110V / 1100 V
a)
MILLI AMP. METER
Range 0-500 MA
b) TONG TESTER
Measuring Range 600 volts, 500 Amp. 1000 ohms
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b) VOLTMETER
Moving iron A.C. P.T. operated voltmeter accuracy ±1.5%, Range: 0-40/80 KV, P.T.
Ratio: 40-80 KV/220 V.
c) AMMETER
Moving Iron A.C. Ammeter
Accuracy ±0.5%
Measuring Range: 0-20 A.
d) DIMMERSTAT
Continuously variable voltage auto-transformer, indoor oil cooled, construction
motorised with single phase supply portable type suitable to work on single phase 50
C/s A.C. supply with base channel and four wheels Input: 240 Volts, single phase 50
C/s A.C.
Capacity: 60 Amp. / 28 A
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Generally tenders are floated by power utilities all over the world. Feasibility of such
tenders are studied and thereafter quoted. Some utilities require prior registration
which involves factory inspection. Registration of the Company as Quality Product
Manufacturer and Supplier with end users, consultants, Turnkey project executors,
service organizations, Government/Private Bodies etc. wherever applicable needs to
be done. Information regarding product requirements are collected through personal
contacts, Newspapers, Magazine, Professional Journal or by any other means.
The techno-commercial team gets involved and the needs of the various potential
customers is assessed for technical requirements. The collected technical data
is compared with company's manufacturing range to identify that the requirement
falls within company's production range.
All inquiries for supply of product are received directly from end users or from other
sources.
Tenders/ Inquiries are scrutinized against the standard Tender Review format.
The salient features of the tender enquiries are listed and discussed with the
concerned departments.
All Technical and Commercial terms including prices are negotiated, wherever
necessary and acceptable, to get maximum advantage.
After acceptance of clients order, P/Os are converted to order confirmation and
released to the Design department for the preparation of drawings and the Bill of
Material (B.O.M.)
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THANKS
SANJEEV KADIAN
Mob. 9812415555
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