Project Report On Prefabricated Substations

PROJECT REPORT ON PREFABRICATED SUBSTATIONS
GURU NANAK DEV ENGINEERING COLLEGE

LUDHIANA
INPLANT TRAINING
AT
CROMPTON GREAVES LIMITED.
TRANSFORMER DIVISION (T1)
KANJUR (EAST), MUMBAI 400 042.
SUBMITTED BY
KUNAL SHARMA
DEPARTMENT ELECTRICAL ENGINEERING
SEVENTH SEMESTER, ROLL NO. !!011!4.
YEAR 2002"200#
GURU NANAK DEV ENGG. COLLEGE, LUDHIANA 1
LUDHIANA
SIX MONTHS INDUSTRIAL TRAINING
REPORT
Undertook Training at
Transor!er Di"ision #T$%
Kan&'r #E%( M'!)ai
S')!itted )* +
K'na, S-ar!a.
Ro,, No. //0$$/1
D21 E,e3tri3a,
Session 4004205
Co!6ton Grea"es Li!ited
A 6ioneering ,eader 7it- !ore t-an 89 *ears o e:6erien3e and
e:6ertise in Hea"* E,e3tri3a, Ma3-iner*( S7it3-gears( Lig-ting( ;ans
and noti3ea),e 6resen3e in E,e3troni3s and Te,e3o!( CGL is
e:tensi"e,* engaged in !an'a3t'ring and !arketing o6erations(
oering an in3redi),e 6orto,io o 6rod'3ts and ser"i3es. In 400$24004(
t-e 3o!6an* 6osted a t'rno"er o Rs. $(800 3rores.
Histor*<
=-at toda* stands as Cro!6ton Grea"es Ltd. -as e"o,"ed ro!
t7o entre6rene'ria, "ent'res )a3k in t-e nineteent- 3ent'r*< T-e
Eng,is- ir! R.E.>. Cro!6ton ? Co( o'nded in $@A@ )* t-e reno7ned
E,e3tri3a, Engineer Co,. Rookes E"e,*n >e,, Cro!6tonB and t-e Indian
ir! Ca!es Grea"es ? Co.( set '6 in $@9@ )* t-e intre6id trader Ca!es
Grea"es( t-at "er* D'i3k,* gre7 into a 6artners-i6 "ent're Grea"es
Cotton ? Co.( 7it- George Cotton( an agent o t-e East India Co.
In $/4A( Cro!6ton ? Co. !erged 7it- ;. ? A. Parkinson o7ned
)* t-e disting'is-ed )rot-ers< ;rank and A,)ert Parkinson 6ioneers in
,arge s3a,e ind'stria, engineering. T-e ne7 enter6rise t-at
!an'a3t'red in Eng,and na!ed Cro!6ton Parkinson ? Co. Ltd.(
a66ointed G.C.C. as its 3on3essionaire in India.
In $/5A( C.P.C. esta),is-ed its 7-o,,* o7ned Indian s')sidiar*
Cro!6ton Parkinson =orks Ltd. at =or,i( M'!)ai 7-i3- !an'a3t'red
a range o e,e3tri3a, and a,,ied eD'i6!ents. A,ong 7it- t-is 3o!6an*( a
sa,es organiEation 3a,,ed Grea"es Cotton ? Cro!6ton Parkinson Ltd.(
in 3o,,a)oration 7it- G.C.C.
T-e IndianiEation 6ro3ess started grad'a,,* ro! $/1A on7ards(
as G.C.C. 6assed into t-e -ands o t-e e!inent Indian ind'stria,ist
La,a Kara!3-and T-a6ar.
T-e 6rogressi"e )'siness asso3iation )et7een C.P.=. ?
G.C.C.P. 3a!e to its ,ogi3a, 3on3,'sion in $/88 7it- a !erger to or!
Cro!6ton Grea"es Ltd. As a res',t o t-is( t-e 3o!)ined a3ti"ities o
!an'a3t'ring( distri)'tion and sa,es( insta,,ation( ser"i3ing and
3ontra3ting 7ere )ro'g-t 'nder t-e 3o!!on !anage!ent o CGL.
In $/8@ Cro!6ton Parkinson Ltd.( UK 7as taken o"er )* Ha7ker
Sidde,e* gro'6 o 3o!6anies. Transor!er !an'a3t'ring o6eration
soon )e3a!e t-e !a&or and inde6endent di"ersion o CGL 7it- ann'a,
sa,es )eing 40F o t-e tota, sa,es. In $/// )ot- Cro!6ton Parkinson
and Ha7ker Sidde,e* gro'6 o 3o!6anies 3a!e to -a"e eD'it*
6arti3i6ation in t-e 3o!6an*( 7-i3- in t'rn -a"e )e3o!e a 6art o t-e
>.T.R. Gro'6.
S-are-o,ding Pattern o CGL
PRODUCT RANGE< Generator( Inter3onne3ting A'to( S')station(
M',ti7inding( Unit a':i,iar*( ;oi, 7o'nd( Dr* T*6e( ;'rna3e D't*(
T-*ristor D't* and Rai,7a* Tra3tion Transor!ers( et3.
$. H*dro T'r)ines< CGL. Man'a3t'res H*drot'r)ines 7it- t-e
te3-ni3a, kno72-o7 ro! Voest A,6ine ? Koss,er G!)-.
PRODUCT RANGE< A:ia,( ;ran3is( and Pe,ton t*6e H*drot'r)ines
3a6a),e o generating 6o7er as a sing,e 'nit o 40M=.
4. S7it3- gears< CGL oers t-e 7idest range o s7it3-gear( ro! t-e
s!a,,est o MCC>Gs to ,arge 100KV S;8 )reakers.
PRODUCT RANGE< Air Cir3'it >reakers #AC>Gs%( Va3''! Cir3'it
>reakers( S;8 Cir3'it >reakers( Instr'!ent Transor!ers( >'s-ings(
OLTCGs( Ca6a3itors.
5. Engineering 6ro&e3ts di"ision< M',ti6,e:ing t-e Co!6an*Gs 7ide
ranging 3a6a)i,itiesB t-e Engineering Pro&e3ts Di"ision 'ndertakes
t'rn ke* 6ro&e3ts ro! 3on3e6t to 3o!!issioning( or generating
stations ? s')stations( trans!ission and distri)'tion ,ines( ind'stria,
3o!6,e:es( rai,7a* tra3tion( i,,'!ination s*ste!s and !an* !ore
a66,i3ations.
PRODUCT RANGE< HT ? LT AC !otors ? generators( ;HP !otors(
;,a!e 6roo !otors( C*3,ogeared !otors( Ad"an3ed "aria),e s6eed
dri"e s*ste!s 7it- !otor 3ontro,,er 6a3kage( DC !otors( Tra3tion
!otors( et3.
PRODUCT RANGE< DOL ? STAR2DELTA Starters( Air 3ir3'it
)reakers( Mo,ded Case Cir3'it >reakers( Contra3tors( Re,a*s( Motor
Contro, Centers( Po7er Contro, Centers( P,'gs and so3kets.
$. Contro, and A'to!ation< T-e 6rod'3t range o t-is di"ision in3,'des
6rogra!!a),e ,ogi3 3ontro,,ers( Sot start energ* sa"ers(
Te!6erat're 3ontro, 'nits( So,id state 6rote3tion re,a*s( and
A'to!ati3 test eD6t. M',ti2task a'to!ation s*ste!s( Co2generation
s*ste!s( Rai,7a* tra3king and signa,ing s*ste!s.
Introd'3tion to t-e Transor!er Di"ision.
Transor!er Gro'6( a 'nit o Cro!6ton Grea"es LTD. started its
o6eration in $/5@ 7it- its irst s'66,* to t-e US ar!*. =it- 5 -ig-,*
so6-isti3ated !an'a3t'ring 6,ants in India at Kanjur, Mumbai(T1)(
Malanpur, Gwalior(T2) and Mandideep( >-o6a,#T5% it is not on,* t-e
,eader in t-e Indian !arket )'t a,so t-e !a&or e:6orter to !an*
3o'ntries. T-e ,argest 6ri"ate se3tor !an'a3t'rer o transor!ers in
India( is CGL. oers t-e 7idest range o 6o7er and distri)'tion
transor!ers and rea3tors in a,, ratings 7it- "o,tages '6to 140K" 3,ass
to ',i,, t-e s6e3ii3 de!ands and ,oad 3onditions o 6o7er stations(
ind'stria,( r'ra,( 'r)an and do!esti3 a66,i3ations. D'ring t-e *ear
400$24004 t-e Transor!er Di"ision at Kan&'r a,one !ade a t'rno"er
o Rs. $A0 !i,,ion. T-e tota, t'rno"er o Transor!er Di"ision in3,'ding
a,, t-e t-ree di"isions or t-e *ear 400$ + 4004 is Rs. 449 !i,,ion.
Present,*( CGL. -as t-ree !an'a3t'ring 6,ants in India(
MALANPUR( G=ALIOR #T4% < Distri)'tion( Medi'! Po7er
Transor!ers and transor!ers or
Ind'stria, a66,i3ations.
It 7as esta),is-ed in t-e *ear $//$ and
-as an area o 40(000 sD.!.
;irst $19 K" C,ass Tra)sor!er.
;irst A4.9 K" C,ass Transor!er in $/14.
T-e transor!er gro'6 -as s'66,ied o"er one !i,,ion KVA. o
transorners '6 to 100KV 3,ass to "ario's insta,,ations. T-e
Transor!er Di"ision -as a3D'ired ISO /00$ and ISO $100 stat's.
De6art!ents O T-e Transor!er Di"ision<
T-e transor!er di"ision di"ided into dierent se3tions. T-e
se3tions o t-e di"ision are done to s!oot-en t-e 7orking o t-e
di"ision so as to in3rease t-e 6rod'3tion. T-e "ario's se3tions are as
o,,o7s <2
$% Marketing.
4% Dra7ing and Design.
5% P'r3-ase and P,anning.
1% Engineering Ser"i3es.
9% H'a,it* Contro,.
8% I!6ro"e!ent !anage!ent.
A% Prod'3tion #S-o6 ;,oor%.
Transor!ers
Transor!ers are a!ong t-e !ost ei3ient e,e3tri3a, !a3-ines
7it- /9F ei3ien3* )eing 3o!!on in ,o7er 3a6a3it* ranges and( 7-i,e
an ei3ien3* o t-e order o //F )eing 3o!!on in t-e -ig-er 3a6a3it*
ranges. T-eoreti3a,,* t-ere is no '66er ,i!it to t-e 6o7er -and,ing
3a6a3it*2trans6ort 3onstraints( -and,ing a3i,ities et3 are t-e ,i!iting
a3tors. Lo7er ,i!it is go"erned )* t-e a,,o7a),e No2Load ,oss.
Transor!ers -a"e a ,arge no. o "aria),es and t-eir
reD'ire!ents dier a great dea,. So )eore designing a transor!er t-e
engineer s-o',d -a"e a good kno7,edege o t-e reD'ire!ents o t-e
3'sto!er( t-e t*6e o &o) to )e 3arried o't( t-e 3onditions at t-e 6,a3e
7-ere t-e transor!er is to )e 'sed and so on. As 6er t-e standards
t-e o,,o7ing s6e3ii3ations sti6',ated )e,o7 s-o',d )e s6e3iied )* t-e
3'sto!er.
$. T*6e o Transor!er + 7-et-er A'to transor!er( Se6arate
7inding transor!er et3.
4. No. o P-ases.
5. ;reD'en3*
1. Rated 6o7er in KVA and ta66ing ranges.
9. Rated "o,tages or ea3- 7inding.
8. Conne3tion To s*!)o,.
GURU NANAK DEV ENGG. COLLEGE,
LUDHIANA 10
A. ReD'ire!ennt o OLTCIO;TC or ,inks.
@. I!6eden3e "o,tage at rated 3'rrent and I 6rin3i6a, ta66ing or
dierent 6air o 7indings.
/. Indoor or o'tdoor t*6e.
$0 T*6e o 3oo,ing and i dierent dierent t*6es o 3oo,ing is
in"o,"ed rated 6o7er or ea3- 3oo,ing.
$$ Te!6erat're Rise and a!)ient te!6erat're 3onditions in3,'de
a,tit'de and in 3ase o 7ater 3oo,ing( 3-e!i3a, ana,*sis o 7ater.
$4 No. o 3oo,ing )anks s6are 3a6a3it* i an*.
$5 Hig-est s*ste! "o,tage or ea3- 7inding.
$1 Met-od o s*ste! eart-ing or ea3- 7inding.
$9 =-et-er 7indings s-a,, -a"e 'nior! or non'nior! ins,'ation
and in 3ase o non 'nior! ins',ation 6o7er reD'en3* 7it-stand
"o,tage o ne'tra, and i!6's,e 7it-stand "o,tage.
$8 ;or 7indings -a"ing -ig-est s*ste! "o,tage greater t-an 500KV
!et-od o die,e3tri3 testing.
$A =it-stand "o,tage "a,'es 3onstit'ting ins',ation ,e"e, o ,ine
ter!ina,s.
$@ Li!itations o trans6ort 7eig-t and !o"ing di!ensions andd an*
s6e3ia, reD'ire!ents i an* o insrta,,ation( asse!),e and
-and,ing.
$/ =-et-er sta)i,iEing 7inding is reD'ired.
LUDHIANA 11
40 O"er,':ing 3onditions or an* ot-er e:e36tiona, ser"i3e
3onditions.
4$ Loading 3o!)inations in 3ase o !',ti 7inding transor!ersand
7-en ne3essar* a3ti")e and rea3ti"e o't6't se6arate,*
es6e3ia,,* in 3ase o !',ti 7inding a'to transor!ers.
44 Detai,s o a':i,,ar* s'66,* "o,tage#or ans( 6'!6s( OLTC( !otor
a,ar! and 3ontro,%
45 Contro,s o ta63-angers.
41 S-ort 3ir3'it ,e"e,s o s*ste!s.
49 Va33'! and 6ress're 7it-stand "a,'es o transor!er tank.
48 Noise ,e"e, reD'ire!ent.
4A No. o rai,s and and rai, g'age or !o"e!ent a,ong s-orter and
,onger a:es.
4@ ;ittings reD'ired 7it- t-eir "i"id des3ri6tion.
4/ An* ot-er a66ro6riate inor!ation in3,'ding s6e3ia, test i an*
and 3a6ita,iEEtion or!',a or ,osses.
Ho7e"er so!eti!es a,, t-ese are not s6e3iied )* t-e 3'sto!er
so CGL -as s-or,isted so!e o t-ese as )asi3 !ini!'! data reD'ired
to start t-e design 7ork.T-e design is !ade )ased '6on t-ese 7-i,e
kee6ing in !ind t-at t-e an* o t-e ,i!its as !entionsed in t-e
s6e3ii3ations ,isted a)o"e are not 3rossed. T-e 7ork o designing is
)asi3a,,* a &o) o !ini!iEing t-e ,osses and 3ost at t-e sa!e ti!e
LUDHIANA 12
!a:i!iEing t-e o't6't( ei3ien3* and in3reasing t-e re,ia)i,it* and ,ie
o t-e eD'i6!ent.
A6art ro! -a"ing a good design( it is i!6ortant t-at t-e
!ateria,s 'sed in t-e transor!ers s-o',d a,so )e o -ig- D'a,it*. T-is
is ne3essar* to ens're 6ro6er 'n3tioning( saet* and re,ia)i,it* o t-e
transor!er not to !ention its ee3t on ,ie o transor!er. >e,o7 are
dis3'ssed so!e o t-e !ateria,s 'sed in transor!er at CGL.
$. CRGO
CRGO #Co,d ro,,ed Grain Oriented% si,i3on stee, is 'sed or t-e
!agneti3 3ir3'it o t-e transor!er. It -as so!e ot-er 3onstit'ents
s'3- as 3ar)on( ni3ke,( 3-ro!i'! a6art ro! si,i3on 7-i3- is t-e !ain
3onstit'ent. CRGO is !ade ro! a erro's )ase. Iron 3r*sta,,iEes into a
)od* 3entered 3')i3 ,atti3e 7it- 3')e edges 6ointing in dire3tion o
easiest !agnetiEa)i,it* and ,o7est 3ore ,oss. T-e s-eets are 3oated
7it- ins',ating !ateria, Car,ite on )ot- sides.
i.

4. Ins',ated Co66er Cond'3tor
LUDHIANA 13
T-e dierent t*6es o 3ond'3tors 'sed or transor!er 7indings are<
i. Pa6er 3o"ered re3tang',ar Co66er 3ond'3tor.
ii. T7in 6a6er 3o"ered re3tang',ar 3o66er 3ond'3tor.
iii. Pa6er 3o"ered Contin'o's,* Trans6osed Cond'3tor #CTC%.
i". T7in trans6osed Co66er 3ond'3tor )'n3-ed 3ond'3tor.
ii% ? i"% are 'sed to i!6ro"e 7inding a3tor.
>are stri6s are !ade o E,e3tro,*ti3 To'g- Pit3-#ETP% gra3e Co66er
#3ond'3ti"it* //.$1F IACS%. Stri6s s-o',d )e 6ere3t,* s!oot- so as o
7it-stand s'rge "o,tages d'ring test and o6eration. Edges are
ro'nded o.
Ad"antages o CTC o"er sing,e re3tang',ar 3ond'3tor.
a% =inding ti!e is red'3ed( sin3e need or -and trans6osition is
e,i!inated.
)% =inding s6a3e a3tor i!6ro"es noti3ea),* 3o!6ared to sing,e
re3tang',ar 3ond'3tors.
3% Edd* ,osses d'e to 3ir3',ating 3'rrent )et7een ad&a3ent t'rns are
red'3ed. T-erore tota, 3o66er ,osses o transor!er d'e to
7inding are red'3ed.
d% It oers an i!6ro"e!ent in !e3-ani3a, strengt- o 7inding.
LUDHIANA 14
Disad"antage o CTC is t-at it is 3ost,* as 3o!6ared to sing,e
re3tang',ar 3ond'3tor.
5. Ins',ating Pa6er
Pa6er is a a)ri3 !ade ro! "egeta),e i)ers and e,ted to or!
7e) or s-eet. Materia,s are i)ro's ro! 6,ants ,ike 3otton( -e!6(
!ani,a( stra7 and 3oniero'sIde3id'o's trees.
Dierent t*6es o ins',ating 6a6er are 'sed ,ike Krat 6a6er o
!edi'! air 6er!ea)i,it*( Krat 6a6er o -ig- air 6er!ea)i,it* and 6ress
6a6er.
CGL 'ses Press 6a6er )e3a'se o )etter 6ro6ert*
T*6es o 6ress 6a6er are
$. Pre3o!6ressed so,id.
4. Sot 3a,endered so,id.
5. Pre3o!6ressed ,a!inated.
1. Sot 3a,endered ,a!inated.
Pro6erties o Pre3o!6ressed >oard are ,isted )e,o7
Sr. No C-ara3teristi3 Va,'e
$. Co!6osition $00F 7ood 6',6
4 Densit* $.$2$.5gI3' 3!
5 Moist're 8F !a:
1 Oi, A)sor6tion /F !a:
LUDHIANA 15
9 Tensi,e strengt-
i. Ma3-ine dire3tion
ii. Cross Dire3tion
$$0 M6a
@9 M6a
8 Co!6ressi)i,it* #air% in oi, 52@F!a:
A
>DV at /0 C
i. $.9!! t-i3k
ii. 5!! t-i3k
iii. 8!! t-i3k
i". @!! t-i3k
59 KV
50KV
50KV
49KV
1. Per!a7ood
Man'a3t'red ro! se,e3ted "eneers #4 !! t-i3k% o)tained ro!
"ario's ti!)ers.
Dried and i!6regneted 7it- ne'tra, 6-eno, or!a,de-*de resin. Used
in areas t-at reD'ire -ig-er !e3-ani3a, and ,o7er e,e3tri3 strengt- ,ike
3oi, 3,a!6ing ring( 3,eat( s'66ort( 3ore( *oke( 3,a!6 7edge ),o3k( )o,t
and n't and ter!ina, )oard.
Sr. No. C-ara3teristi3 Va,'es
$ Densit* $.$2$.4 gI3' 3!
4. Moist're 3ontent AF!a:
5 Oi, a)sor6tion 8F !a:
1 Tensi,e strengt- $04 M6a
9 Co!6ressi"e strengt- $@9 M6a
8 S-ear strengt- 90 M6a
A E,e3tri3 strengt-
LUDHIANA 16
i. ;,at7ise
ii. Edge7ise
1 KVI!!
80 KVI!!
9. Ins',ating oi,
Oi, -as 6ri!ari,* t7o 'n3tions
$. To a3t as e,e3tri3a, ins',ator
4. To a3t as 3oo,ant to dissi6ate -eat ,osses.
Ra7 !ateria, or oi, is a ,o7 "is3osit* ,')e ter!ed as
Transor!er Oi, >ase Sto3k#TO>S% a !inera, oi,. O)tained on
ra3tiona, distan3e and s')seD'ent treat!ent and reining )* a3id
treat!ent. It -as o'r !a&or generi3 3,ass o organi3 3o!6o'nds2
6arains( na6t-a,enes( aro!ati3s and o,eins. It is a 6're -*dro3ar)on
!inera, oi,.
Sr. No C-ara3teristi3 Va,'e
$.
Densit* at 4A C
0.@/ gI3' 3!
4 Intera3ia, tension 0.01NI!
5 ;,as- 6oint#Pensk*
Marten%
$10 C
1 Po'r 6oint
2/C
9 Corrosi"e S',6-'r Non Corrosi"e
8 E,e3tri3a,
Strengt-#>DV%J
i. As re3ei"ed
ii. Ater ;i,tration
50 kV#r!s.%
90 kV#r!s.%
A Die,e3tri3 Dissi6ation
a3tor at /0C #tan %K
0.009
@ S6e3ii3 Resistan3e
i. at /0C 50X$0
$4
3!
LUDHIANA 17
ii. at 4AC 900X$0
$4
3!
/ =ater Content 90 66! )* 7t
$0 Presen3e o o:idation
in-i)itor
Oi, s-o',dnGt 3ontain
antio:idant additi"es.
>DV2>reakdo7n Vo,tage or standard ga6 o 4.9!! )et7een
e,e3trodes.
Note< It is n'!eri3a,,* eD'a, to sine o ,oss ang,e# a66ro: eD'a, to
tan o ,oss ang,e or die,e3tri3s% is 'sed as a too, to indi3ate t-e
D'a,it* o ins',ation. Hig- "a,'e o DD; indi3ates 6resen3e o
3onta!inants.
8. Str'3t'ra, Stee,
Used !ain,* in s-eet and 6,ate or! in a)ri3ation o transor!er
tank( radiator( 3onser"ator( 3,a!6 6,ate( end ra!e( !ars-a,,ing )o:(
3a),e )o:( ro,,er( t'rret( ins6e3tion 3o"er et3.
Design o "ario's 6arts o transor!er
$. Design o !agneti3 Cir3'it i.e. 3ore design
4. =inding Design
5. Ins',ation Design
1. T*6e o Coo,ing
9. Vo,tage reg',ation and Ta6 3-anger
LUDHIANA 18
$. Design o !agneti3 3ir3'it or 3ore design
Design o !agneti3 3ir3'it o transor!er is )ased on t-e
o,,o7ing a3tors.
i. Rating o transor!er and 6eror!an3e.
ii. O6erating 3onditions
iii. Trans6ort ,i!itations.
Design o 3ore -as a signii3ant )earing on o"era,, e3ono!* o
transor!er. >* in3reasing t-e o6erating "a,'e o > t-e net 7t o 3ore
3an )e red'3ed( )'t t-is ,eads to 3orres6onding in3rease in 3ore ,oss.
T-ereore o6ti!'! "a,'e o !agneti3 ,': densit* -as to )e kno7n. >*
'sing a 6ro6er 3ore design it is 6ossi),e to -a"e
i. Hig-er re,ia)i,it*
ii. Red'3tion in iron ,oss and !agnetiEing 3'rrent
iii. Lo7ering in iron ,oss and ,a)or 3ost.
i". A)ate!ent o noise ,e"e,s.
Vario's t*6es o !agneti3 3ir3'its 'sed or designing t-e 3ore
are2
$. Sing,e 6-ase 5 ,i!)ed 3ore.
T-is is genera,,* 6reerred or sing,e 6-ase transor!er and is
!ore e3ono!i3a, t-an 4 ,i!)ed 3onstr'3tion. =inding is on t-e 3entra,
,i!). T-e A':i,iar* ,i!) and *oke are -a, t-at o !ain ,i!) in
di!ensions.
LUDHIANA 19
4. Sing,e 6-ase 4 ,i!)ed 3ore.
Used or ,arger ratings )e3a'se i 7indings are 6,a3ed on a
3entra, ,i!) t-e siEe is ,arge and 3annot )e trans6orted. Cross2
se3tiona, area o ,i!)s and *oke is identi3a,. T-ereore 3ores are
)',kier. Per3entage ,eakage rea3tan3e is -ig-er t-an in sing,e
6-ase t-ree ,i!)ed transor!er.
5. T-ree 6-ase 5 ,i!)ed 3ore.
Used or t-ree 6-ase s!a,, and !edi'! 6o7er ratings. =inding
o ea3- 6-ase is 6,a3ed on one ,eg.
LUDHIANA 20
1. T-ree 6-ase 92,i!)ed 3ore.
;or ,arge 6o7er ratings( 3ores -a"e to )e )'i,t in ,arge
dia!eters. In 3ase o t-ree 6-ase 5 ,i!)ed 3ores t-e *oke -a"e t-e
sa!e dia!eter as t-e ,i!)s. In 3ase o ,arger dia!eters o"era,,
3ore -eig-t 7i,, go '6 ,eading to trans6ort 6ro),e!. T-ereore *oke
3ross se3tion is red'3ed #and t-ereore *oke -eig-t% )* a66ro:.
10F or !ore )* 6ro"iding a':i,iar* 6at-.
Core Cross Se3tion
Idea, s-a6e o 3ore is a 3ir3,e( )'t t-at 7o',d reD'ire ea3-
,a!ination o dierent dia!eter( 7-i3- is 6ossi),e )'t 'ne3ono!i3a,.
T-ereore as a 3o!6ro!ise 3ore 3ross se3tion is !ade )* ,a!inations
o "ar*ing 7idt- and 6a3ket -eig-ts in s'3- a 7a* t-at o"era,, se3tion
LUDHIANA 21
a66ro:i!ates a 3ir3,e. Oi, d'3ts are ne3essar* or 3oo,ing ,est t-e -ot
s6ot te!6erat're rises dangero's,* and n'!)er o d'3ts de6ends on
3ore dia!eter and s6e3ii3 3ore ,oss. C,a!6 6,ates are reD'ired on
eit-er side o ,a!inations or ee3ti"e,* 3,a!6ing t-e ,a!inations.
Stee, s-eet ,a!inations( oi, d'3ts and 3,a!6 6,ates s-o',d
,ie 7it-in 3ore 3ir3,e. Net 3ross se3tiona, area is 3a,3',ated ro!
di!ensions o "ario's 6a3kets and a,,o7an3es !ade or s6a3e ,ost
)et7een ,a!inations kno7 as sta3king a3tor. Area is a,so ded'3ted or
oi, d'3ts. Ratio o net 3ross se3tion and gross 3ross se3tion o 3ir3,e is
3a,,ed 'ti,iEation a3tor #U;%. U; i!6ro"es 7it- in3rease in ste6. >'t
t-is in3reases !an'a3t'ring 3ost.
Se,e3tion o 3ore dia!eter
Core dia!eter de6ends '6on n'!)er o a3tors ,ike rating(
6er3entage i!6edan3e )et7een 7indings( )asi3 ins',ation ,e"e,
trans6ort -eig-t( o"er,':ing reD'ire!ent( t*6e o 3ore and D'a,it* o
stee,. It is air,* 3o!6,i3ated to deri"e 'ni"ersa, and e:a3t or!',a or
deter!ining dia!eter. In 6ra3ti3e 3ore dia!eter is se,e3ted ro!
si!i,ar designs a,read* a"ai,a),e( kee6ing in "ie7 ,i!iting 3onditions as
!entioned a)o"e. >ased on t-is g'aranteed 6ara!eters i.e.
6er3entage i!6edan3e and ,osses are 7orked o't. Core dia!eter is
ad&'sted to !eet g'aranteed 6ara!eters.
As a t-'!) r',e t-e dia!eter !a* )e 3a,3',ated )*
LUDHIANA 22
D L 1K#KVA%
$I1
Ro'nded o to a s'ita),e integer.
Variation o 3ore dia!eter
In3reasing t-e 3ore dia!eter in3reases t-e 3ross se3tion.
T-ereore in3reasing VIT( 7-i3- red'3es no. o t'rns in "ario's
7indings. Per3entage rea3tan3e )et7een 7indings is dire3t,*
6ro6ortiona, to t-e no. o t'rns and dia!eter o "ario's 3oi,s and is
a,so in"erse,* 6ro6ortiona, to VIT ad 3oi, de6t-. In order to -a"e
s6e3iied rea3tan3e( in3reased 3ore dia!eter ne3essitates red'3tion in
3oi, de6t- and in3rease in 3oi, di!ensions in ,atera, dire3tion( 7-i3-
,eads to red'3tion in 3ore -eig-t and in3rease in 3ore ,eg 3enters. In
s6ite o red'3tion in 3ore -eig-t d'e to in3rease in dia!eter o"era,,
7eig-t o 3ore stee, in3reases( 7-i3- a,so in3reases no ,oad ,oss o
transor!er. A,so( red'3ed no. o t'rns in 7indings e"en 7it- ,arger
,engt- o !ean t'rn res',ts in red'3ed Co66er 7eig-t 7-i3- a,so
red'3es 3ore ,oss o transor!er.
Li!)
Dia!eter in
!!
N'!)er
o ste6s
Li!)
Dia!eter in
!!
N'!)er o
Longit'din
a, d'3ts o
8 !!
7idt-
M$00 U6to 1
$002$90 9 5902100 $
LUDHIANA 23
$902900 8 1002190 4
9002A90 A 1902990 5
A902@90 @ 9902890 1
@902$000 /2$0 8902A90 9
Ta),e s-o7ing t-e n'!)er o ste6s and oi, d'3ts or dierent
dia!eters.
;or an* 6arti3',ar 3ore dia!eter )ased on ot-er design
3onsideration t-is gi"es not on,* o6ti!'! area t-ere)* red'3ing > and
iron ,osses. I!6ro"e!ent in U; in3reases 3ore area. T-ereore "a,'e
o VIT or an* 6arti3',ar 3ore dia!eter o s6e3iied ,': densit*. T-is
res',ts in red'3tion o 3o66er. T-ereore 3ore area o6ti!iEation res',ts
in )etter e3ono!* o transor!er design.
Se,e3tion o Leg ,engt-
Leg ,engt- de6ends '6on !a:i!'! trans6ort -eig-t( t*6e o
7agon to )e 'sed or trans6ortation and t*6e o 3ore se,e3ted. ;or
,arge ratings !a: "a,'e o ,eg ,engt- gi"es o"era,, e3ono!*. Lo7er
ratings( !a* -a"e red'3ed ,eg ,engt- to gi"e o"era,, e3ono!*. >*
red'3ing ,eg ,engt-( rea3tan3e o t-e transor!er in3reases and "i3e
"ersa.
Se,e3tion o ;,': Densit*
LUDHIANA 24
Va,'e o ,': densit* is 3-osen to s'it g'aranteed 6eror!an3e.
Nor!a,,* ,': densit* is 3-osen near knee 6oint o t-e >2H 3'r"e.
AdeD'ate !argin s-o',d )e ke6t to take 3are or s*ste! 3onditions
,ike o"er,':ing( reD'en3* and "o,tage "ariations. In 3ertain 3ases > is
red'3ed to ,i!it noise ,e"e, in transor!er.
In,'en3e o "ar*ing >
Kee6ing ot-er 6ara!eters 3onstant and in3reasing > res',ts in
-ig-er VIT. T-ereore no. o t'rns are red'3ed. Ee3t o in3rease o
>on rea3tan3e is si!i,ar to t-at o in3rease in 3ore dia!eter. To !eet
reD'ired 3ross se3tion 3oi, de6t- is red'3ed and ,atera, di!ension o
3oi,s are in3reased. In3reased > 7it- red'3ed 3ore stee, 7eig-t
res',ts in -ig-er no ,oad B,oss o transor!er. Red'3ed no o t'rns in
7inding res',ts in ,o7er Co66er 7eig-t and ,oad ,oss. A,so red'3ed >
3a'ses in3reased 3ore stee, 7eig-t( ,o7er no ,oad ,oss and in3reased
Co66er 7eig-t and ,oad ,oss.
Para!eter In3reased 3ore
dia!eter
In3reased > In3reased ,eg
,engt-
Co66er 7eig-t De3reases De3reases In3reases
Load ,oss De3reases De3reases In3reases
Core stee,
7eig-t
In3reases De3reases De3reases
No ,oad ,oss In3reases In3reases De3reases
LUDHIANA 25
;or asse!),ing o 3ore ,a!inations t-e o,,o7ing t*6es o 3orner &oints
are !ore 3o!!on
a% Inter,ea"ed 2 It is si!6,est ro! !an'a3t'ring 6oint o "ie7 )'t in
t-e 3ross graini Eones ,':es ,ea"eI enter t-e ,a!inations in
6er6endi3',ar dire3tion and t-ereore ,osses are -ig-er. A,so it is
ne3essar* to -a"e ins',ation sa6a3ers )et7een *okes and ,i!)s as
to 6re"ent 3ond'3tion )et7een se6arate ,a!inations. S6a3ers
3a'se ,arge in3rease in t-e no ,oad 3'rrent.
)% Mitred + Ad"antages are t-at t-is t*6e o &oint 6ro!otes ,': ,o7
indire3tion o grains and t-ere is de3rease in no2,oad 3'rrent.
4. Se,e3tion o t*6e o =inding
D'e 3are !'st )e taken 7-i,e designing 7inding to ens're its
-ea,t-iness d'ring nor!a, and a',t 3onditions. =indings !'st )e
e,e3tri3a,,* and !e3-ani3a,,* strong to 7it-stand )ot- o"er"o,tage
'nder in3iden3e s'rges and !e3-ani3a, stresses d'ring s-ort
3ir3'it 3onditions. Te!6erat're o 7indings at rated( o"er,oad and
s-ort 3ir3'it 3onditions s-o',d )e 7it-in ,i!its( ens'ring 6ro6er ,ie
o transor!er.
Transor!ers are !an'a3t'red or 7ide ranges o o't6't
"o,tages and t-e rea,iEation o t-ese reD'ire!ents is 6ossi),e on,*
LUDHIANA 26
)* 'sing dierent kinds o 7indings. Dierent kinds o 7indings are
des3ri)ed )e,o7.
$. Distri)'ted Cross o"er 7indings
T-ese are s'ita),e or 3'rrent '6to 40 A. =ires are o 3ir3',ar
3ross se3tion !ost,* 6reerred o HV 7inding o s!a,,
transor!er in distri)'tion range. No. o s'3- 3oi,s are &oined in
series and s6a3ed 7it- ),o3ks or ins',ation and d'3t or 3oo,ing.
4. S6ira, =inding
T-ese are 'sed '6to 55KV ,o7 3'rrent ratings.
Re3tang',ar 3ond'3tors are 'sed. Cond'3tors are 7o'nd 3,ose,*
in a:ia, dire3tion 7it-o't radia, d'3ts )et7een t'rns. Nor!a,,*
7o'nd on )ake,ite or 6ress)oard 3*,inder.
LUDHIANA 27
Nor!a,,* 7o'nd on ,at side( so!eti!es 7o'nd on edge.
=indings !a* )e sing,e ,a*er or !',ti,a*er t*6e. Trans6osition is
's'a,,* not ne3essar*. ;or dr* t*6e transor!ers )are
re3tang',ar 3ond'3tors are 'sed and t-e t'rns are se6arated
ro! ea3- ot-er )* 'sing a No!e: 3o"ered 3ond'3tor a,ong7it-
t-e )are 3ond'3tors.
5. He,i3a, =inding
T-ese are 'sed in LV and -ig- 3'rrent ratings No. od 3ond'3tors are
'sed in 6ara,,e, to or! $ t'rn. T'rns 7o'nd in -e,i: a,ong a:ia,
dire3tion and ea3- t'rn is se6arated ro! ne:t )* d'3t. =inding !a*
-a"e one or !ore ,a*ers. ;or !',ti,a*er 7indings s'33essi"e ,a*ers
are 7o'nd in o66osite sense.
LUDHIANA 28
1. Contin'o's Dis3 =inding
T-is t*6e is 'sed or "o,tages )et7een 55KV and $54KV and
!edi'! 3'rrent ratin. Coi,s 3onsist o se3tions 6,a3e in a:ia, dire3tions
7it- d'3ts )et7een t-e!. Ea3-se3tion is a ,at 3oi, -a"ing !ore t-an
one t'rnand ea3- t'rn !a* itse, 3o!6rise o one or !ore 3ond'3tors
in 6ara,,e,. Se3tions are in series )'t7it-o't an* &oi!nts)et7een t-e!.
T-isis a3-ie"ed )* !et-od o 3o,,a6sing and re)'i,Nding t-e dis3s.
Dis3s are se, s'66orting( !e3-ani3a,,* strong and3an 7it-stand a:ia,
or3es. A,so it 3an -a"e ra3tiona, no. o t'rns.
LUDHIANA 29
In CDD and He,i3a, 7indings trans6ositions are e!6,o*ed.
Trans6ositions !a* )e 3o!6,ete or 6artia,.
9. Inter,ea"ed dis3 =inding
Disad"antage o CDD is t-at strengt- against i!6',se "o,tageis
not adeD'ate "o,tage a)o"e $19KV.T-is is i!6ro"ed )* inter,ea"iong
t'rnsin s'3- a as-ion t-at ad&a3ent 3ond'3tors )e,ong to t7o dierent
t'rns.
8. S-ie,ded La*er =inding
T-is 7inding is 'sed genera,,* or star 3onne3ted transor!er
-a"ing graded ins',ation or "o,tages greater t-an$54KV 3,ass.
LUDHIANA 30
=inding 3onsist o no. o 3on3entri3 s6ira, 3oi,s arranged in ,a*ers.
La*ers are arranged )et7een t7o 3on3entri3 3*,indri3a, s-ie,ds
3onne3ted one to ea3- end o 7inding.
La*ers are se6arated )* oi, d'3ts and 'n)onded 6a6er 3*,inders.
Ad"antage o 7inding is t-at re,ati"e,* 'nior! distri)'tion o s'rge
"o,tages t-ro'g-o't t-e 7inding is a3-ie"ed. ;or ,arge 3'rrent and
-ig-er densit* o ,eakage ,': trans6osition is 'sed.
Heat Transer in 7indings
Us'a,,* -eat transer takes 6,a3e )* oi, 3ir3',ation )* 3on"e3tion.
Heat ro! inner 6arts o 7inding is transerred to its o'ter 6arts )*
3ond'3tion. T-er!a, 3ond'3ti"it* o 3o66er is !a* ti!es -ig-er t-an
t-at o ins',ating 6a6er on t-e 3ond'3tor. T-e 6a6er tries to i!6ede
3ond'3tion o -eat and t-i3ker t-e 6a6er !ore is t-e i!6edan3e.
T-i3kness o 6a6er 3o"ering on t-e 3ond'3tor -as to )e a
)a,an3e )et7een reD'ire!ent o e,e3tri3a, ins',ation and t-er!a,
i!6edan3e. Coo,ing d'3ts are 6ro"ided radia,,* or a:ia,,*.
Ins',ation Design
Ins',ation Str'3t're 3an )e )road,* 3,assiied as 6er t-eir ,o3ation in
transor!er.
LUDHIANA 31
a% Minor Ins',ation +It reers to ins',ation )et7een dierent 6arts o
7inding ,ike ins',ation )et7een t'rns( ,a*ers et3.
i.% Ins',ation o 3ond'3tors is genera,,* 6a6er 7ra66ed aro'nd
t-e 3ond'3tor. ;or CTC indi"id'a, strands are 3oated 7it- a
,a*er o ena!e, )eore ina, 7ra66ing o 6a6er.
ii.% Ins',ation )et7een t'rns is 6ro"ided )* 3ond'3tor ins',ation
or )* 3ond'3tor ins',ation a,ong 7it- radia, oi, d'3ts or!ed
)* 'sing do"etai, ),o3k. T-i3kness o ins',ation deter!ined )*
"o,tages #6o7er reD'en3* or i!6',se% a66earing )et7een
dierent 3onditions o t-i3kness and t-er!a, 3onsiderations.
iii.% Ins',ation )et7een ,a*ers o s-ie,ded ,a*er 7inding 3onsists
o a:ia, oi, and 6a6er 3*,inders. In HV 7inding end t'rns are
reinor3ed to take 3are o non ,inear distri)'tion o i!6',se
"o,tage.
)% Ma&or ins',ation + Co!6rises o ins',ation 7inding to eart- and
transor!er 3ore( ot-er 7indings o sa!e 6-ase and )et7een one
6-ase and ot-er. Ins',ation )et7een dierent 7indings and inner
7indings to 3ore 3onsists o 6ress)oard 3*,inder se6arated )* oi,
d'3ts.
Press)oard )arriers are 6ro"ided )et7een 7indings o dierent
6-ases and )et7een 7indings and tank. Ends o 7inding are
LUDHIANA 32
ins',ated ro! *okes )* adeD'ate no. o ang,e ringsIang,e 7as-ers
de6ending '6on "o,tage 3,ass.
Prote3tion o transor!er against s'rges
Transor!er 7indings res6ond to s'rge "o,tages as a s*ste! o
C and L net7ork. ;or irst e7 !i3rose3onds ater a6O6,i3ation o
i!6',se( 7indings )e-a"e as 3a6a3itan3e net7ork. S')seD'ent,* t-e
se, and !'t'a, ind'3tan3es 3o!e into 6,a* and i!6art os3i,,ator*
nat're to "o,tge a66earing at dierent 6arts o 7inding.
;or testing transor!er against s'rges a standardiEed 7a"e is
'sed 7-i-3- is $.4s at t-e 7a"eront and 90s at t-e 7a"e tai,. T-is
standardiEation is to )e done )e3a'se s'rges !a* )e d'e to ,ig-tning
dis3-arge( eit-er in "i3init* o ,ine or ,ine itse, and !a* -a"e
e:tre!e,* 3o!6,i3ated 7a"eor!.
L #CgICs%
$I4
Vo,tage at distan3e at : ro! ne'tra, end is e:6ressed as
V: L V! sin- :
LUDHIANA 33
sin-
on,* or L0 distri)'tion is ,inear. ;or ot-er "a,'es o "o,tage
distri)'tion is non2,inear and "o,tage gradient at ,ine end is ti!es
t-e ,inear "o,tage gradient. D'e to t-is e:tra strain is e:erted on
ins',ation )et7een t'rns at t-e ,ine end o HV 7inding. T-ereore
so!eti!es end t'rns are reinor3ed 7it- e:tra ins',ation !ateria,.
Use o e,e3trostati3 s-ie,d at t-e ,ine end o dis3 7inding -e,6s in
i!6ro"ing non ,inearit* o initia, "o,tage distri)'tion. T-e s-ie,ds are
3onne3ted e,e3tri3,a,,* to end se3tion. >eing in 3,ose 6ro:i!it* o
t-e se3tion t-ere e:ist a ,arge 3a6a3itan3e )et7een s-ie,d and t-e
t'rns o t-e end se3tion. D'e to additiona, 3a6a3itan3e initia,
"o,tage distri)'tion in t-e end se3tion )e3o!es !ore ,inear.
Coo,ing o transor!er
T*6es o 3oo,ing t-at is 'sed inransor!er
$. ONAN#Oi, Nat'ra, Air Nat'ra,% < Used or s!a,,er ratings o
transor!ers. Heat dissi6ation is ro! transor!er oi, to
at!os6-eri3 air )* nat'ra, !eans.
LUDHIANA 34
4. ONA;#Oi, Nat'ra, Air ;or3ed% < A'g!ented rate o -eat
diss6ation )* 'sing ans or ),o7ing air on 3oo,ing s'ra3es.
Heat transer rate is i!6ro"ed.
5. O;A;#Oi, ;or3ed Air ;or3ed% < Sti,, )etter rate o 3oo,ing
sin3e oi, is a,so or3ed to 3ir3',ate )* !eans o oi, 6'!6.
O;A; is 3o!6a3t and o33'6ies ,ess s6a3e.
1. O;=;#Oi, or3ed =ater ;or3ed% < T-e a3t t-at a!)ient
te!6erat're o 7ater is a,7a*s ,ess t-an t-at o air( so it is
'sed as )etter -eat transer !edia. PrereD'isite is
a"ai,a)i,it* o s'i3ient D'antit* o 7ater.
9. ;or3ed Dire3ted 3oo,ing < Sti,, )etter rate o -eat dissi6ation
is a3-ie"ed or -ig-er rating transor!er. Arrange!ent are
6ro"ided or dire3ting oi, ,o7 t-ro'g- 6redeter!ined 6at-s.
On t-is )asis 7e -a"e ODA; and OD=; 3oo,ing.
Coo,ing Arrange!ents
$. Tank !o'nted radiators < T-is t*6e is 'sed or s!a,,er ratings
o transor!er. Radiators 3onne3ted to tank 7it- an
inter6osing "a,"e at t-e to6 and )otto! . Hot oi, enters
radiators ro! to6 and ater -eat dissi6ation goes )a3k in tank
ro! )otto!.
LUDHIANA 35
4. >anked Radiators < Radiators are arranged so as to or! a
)ank. T-is is a ne3essit* 7-en transor!er rating is -ig-er
and tota, no. o radiators reD'ired to dissi6ate ,osses are
!ore. So instead o !o6'nting radiators on transor!er t-e*
are !o'nted on -eaders s'66orted on gro'nd.
PROCEDURE ;OR THE TRANS;ORMER MANU;ACTURE
T-e !o!ent a 3'sto!er order is re3ei"ed 6,anning 7ing -as to i,, t-e
dates N 7eeks de6ending '6on transor!erti!e 3*3,e in stage
3o!6,etion 3o,'!s#Re3tng',ar ),anks% o t-e ,o7 diagra! )* 7orking
)a3k i.e starting ro! dis6at3- to )a3k7ards. Ater t-ese dates I 7eeks
are 3-e3ked and a66ro"ed )* 6rod'3tion 3-ie( 3o6ieso t-ese ,o7
diagra!s d',* i,,ed or ea3- trasnsor!er se6arate,* is sent to
design ( !ateria, !anage!ent #P'r3-ase% ( a,, eeders asse!),*
se3tions o 6rod'3tion area (3o!!er3ia, and -ead o t-e 6rod'3t.
A 7eeke,* re"ie7 !eeting 7it- a,, a)o"e des3ri6ti"es is -e,d and
!onitored or itGs a3-ie"e!ents. A,, dis3ri6ti"es o,,o7 t-e sa!e dates
s6e3iied on t-e ,o7 diagra! to a"oid 3on'sion.
;or so!e 'na"ioda),e reasons (i an* a3ti"it* is getting de,a*ed
a)nor!a,,*(ot-er 3onne3ted a3ti"ities3an )e s,o7ed #not sto66ed% to
a"oid !is!at3- in 6rod'3tion.
LUDHIANA 36
In t-e 6resent da* s3enario o transor!er )'siness ( !eeting s-ort
de,i"eries 7i,, )e a great )oon.
Ins',ating Oi, Testing
$% Disso,"ed Gas Ana,*sis
Disso,"ed gas Ana,*sis is a "er* 6o7er', te3-niD'e to ind
o't in3i6ient a',ts 7it-in t-e transor!er.Certain gases are
6rod'3ed )* de3o!6osition o oi, and I or 6a6er ins',ation 7-en
transor!er 'ndergoes a)nor!a, t-er!a, or E,e3tri3a, Stresses and
t-ese gases get disso,"ed in oi,. T-e 3o!6osition and D'a,it* o
gases generated is de6endent on t-e t*6e and se"erit* o t-e a',t (
reg',ar !onitoring o t-ese disso,"ed gases re"ea,s 'se',
inor!ation a)o't -ea,t-iness o a transor!er and 6rior inor!ation
o a',t 3an )e -ad o)ser"ing t-e trend o "ario's gas 3ontents.
4% =ater Contents
Presen3e o =ater in oi, is -ig-,* 'ndesira),e sin3e it ad"erse,*
ae3ts itGs die,e3tri3 6ro6erties. As 6a6er is -ig-,* -*gros3o6i3 in
nat're 7-en transor!er is i,,ed 7it- oi, ( it a)sor)s t-e !oist're
ro! oi,.
Die,e3tri3 Strengt-
LUDHIANA 37
AC "o,tage is a66,ied )et7een t-e t7o E,e3trodes and t-e )reak
do7n "o,tage o t-e ins',ating oi, is re3orded. T-is Vo,tage is
indi3ati"e o t-e so,id i!6'rities and 7ater 3ontents 6resent in oi,.
5% S6e3ii3 Resistan3e
A,so 3a,,ed resisti"it* ( is DC resistan3eo "o,'!e o oi, 'nit
3rossse3tiona, area and 'nit ,engt-. Pre"a,ent 'nit is o-!23!. It
is desira),e to -a"e s6e3ii3 resistan3e o oi, as -ig- as 6ossi),e.
It "aries 7it- te!6rat're o oi, # an in3rease in te!6rat're
red'3es t-e resisti"it*%. Resisti"it* o oi, red'3es 3onsidera),*
d'e to 6resen3e o !oist're ( a3idit* and so,id 3onta!inations.
1% Die,e3tri3 Dissi6ation ;a3tor
Die,e3tri3 Dissi6ation ;a3tor is a,so kno7n as tan de,ta or ,oss
a3tor. It is !eas're o i!6ere3tion o die,e3tri3 nat're o oi, . ;or
good oi, tan de,ta s-o',d)e as ,ess as 6ossi),e. A -ig- tan de,ta is
an indi3ation o 6resen3e o 3onta!ination s'3- as so,'),e
"arnis-es ( resins e.t.3.
$% A3idit*
T-e A3idit* o oi, is a !eas're o itGs a3idi3 3onstit'ents or
3onta!inants . t-e a3idit* o oi, is e:6ressed in !i,,igra!s o KOH
reD'ired to ne'tra,iEe t-e a3ids 6resent in a gra! o oi,.
T-is is a,so 3a,,ed ne'tra,isation n'!)er . A3idit* o Ne7 oi,s is
a)nor!a,,* "er* ,ess. T-e o:idation o oi, 6rod'3e a3ids and t-e
LUDHIANA 38
a3idit* o oi, t-'s s,o7,* in3reass7it- ageing o transor!er oi,. T-e
a3ids are -ar!', to so,id ins',ation and 'rt-er a33e,arate
o:idation o oi,.

DRY TYPE TRANSFORMER
A transor!er in 7-i3- t-e 3ore and 7inding are not in an ins',ating
,iD'id !edi'!. MIS Cro!6ton Grea"es oering a s'6erior dr* t*6e
transor!er to t-e 3'sto!er )* e!6,o*ing a !ore re,ia),e
i!6regnation s*ste! 'sing 6o,*ster!ide resin na!e,* Va3''!
Press're I!6regnation S*ste! #VPI%.
Need o dr*2t*6e transor!er
In order to 3,ear,* 'nderstand and a66re3iate t-e 'niD'e ad"antage
oered )* Dry-type Transformer o"er Oil illed Transformer( a
3o!6arati"e ana,*sis is !ade )et7een t-e t7o.
DISADVANTAGES O; MINERAL OIL IMPREGNATED SPSTEM<
In t-e transor!er ind'str* t-e 'se o !inera, oi, as an ins',ating
I3oo,ing !edi'! is 7e,, kno7n. Ins6ite o t-e a66arent
o"er7-e,!ing 3ost ad"antages and its 6redo!inant 'sage( t-e
!inera, oi, i!6regnated s*ste! -as se"era, disad"antages( 7-i3-
are as o,,o7s <
1. A;;INITP TO MOISTURE
T-is s*ste! -as got a "er* -ig- ainit* to a)sor) en"iron!enta,
!oist're( 7-i3- !a* not )e 3onsidered a dire3t disad"antage( )'t
LUDHIANA 39
t-e die,e3tri3 integrit* o t-e s*ste! is ae3ted )* t-e !oist're
3ontent. T-is 6ro6ert* i!6oses a reD'ire!ent o !onitoring and
3ontro,,ing t-e !oist're 3ontent d'ring t-e o6erating ,ie o t-e
s*ste! and i neg,e3ted 3o',d 6ossi),* ,ead to its )reakdo7n.
2. MECHANICAL STRENGTH
T-e Die,e3tri3 #oi,% does not add to t-e !e3-ani3a, strengt- o t-e
a3ti"e s*ste!. In a3t it is t-e 3e,,o's s*ste! t-at 3onstit'tes )',k o
t-e ins',ation in t-e a3ti"e asse!),* t-at 3ontri)'tes to t-e
!e3-ani3a, strengt- ,i!its o t-e transor!er d'ring nor!a, and
a)nor!a, #s-ort 3kt% sit'ation and its a)i,it* is ae3ted )* ainit* to
!oist're and aging.
3. POOR ;IRE SA;ETP
T-e oi,2i!6regnated s*ste! is not sae or indoor 'se )e3a'se )ot-
3e,,',ose and t-e oi, -a"e 3o!6arati"e,* ,o7 ire26oints. More o"er(
7-en in"o,"ed in a ire( t-e* 3ontri)'te a "er* -ig- o't6't o -eat
energ*.
4. LIMITATION O; OPERATING TEMPERATURE
T-e 'se o oi, a,so i!6oses an o6erationa, ,i!it o no!ina,
te!6erat're $093 #3,ass QaG%( 6eriodi3 6eak o $10 3 and a',t
te!6erat're o 490 3. T-is a,so re,e3ts on t-e ,o7 o"er,oad
3a6a3it* o s'3- a s*ste!.
5. HUGE AND >ULKP
T-ese s*ste! are )',k* in siEe and 7eig-t )e3a'se o t-e 6resen3e
o radiators( and oi, t-eir 3o!!issioning is so!eti!es dii3',t and
takes ,onger ti!e.
LUDHIANA 40
6. HIGH L.T. CA>LING COST
T-e 3ost in3'rred on L.T. Ca),ing is -ig- sin3e t-is s*ste! 3annot
)e ,o3ated 3,ose to t-e ,oad 3enters or 3ons'!ers.
A6art ro! t-e a)o"e !entioned disad"antages( oi,2i,,ed
transor!er s'er ro! t-e ,i!itation t-at t-e* 3an not )e 'sed in
s6e3ii3 a66,i3ation areas ,ike -ig- a!)ient te!6erat're areas in
Stee, Ind'stries( -ig-,* 3orrosi"e areas in C-e!i3a, Ind'str*( and in
'ndergro'nd insta,,ations et3.
A,, t-ese disad"antages 3an )e o"er3o!e )* t-e 'se o D!"-T"#$
Transor!er t-at oer a saer( !ore re,ia),e o6eration. More o"er(
t-is reD'ires no or neg,igi),e !aintenan3e.
VPI RESIN IMPREGNATED DRP TPPE TRANS;ORMER
INTRODUCTION <
Cro!6ton Grea"es !an'a3t'res a 3o!6re-ensi"e range o
distri)'tion( 6o7er and s6e3ia, transor!ers. T-ere is 3ontin'os eort
on t-e 6art o t-e 3o!6an* to kee6 a)reast o t-e ,atest te3-no,og*
res',ting in i!6ro"ed design and !an'a3t're o "er* -ig- D'a,it*
6rod'3ts( tai,ored to t-e s6e3ii3 need o dis3ri!inating 3'sto!ers.
E6o:* resin i!6regnated )* VPI 6ro3ess is a ne7 generation o dr*
t*6e transor!er -a"ing )etter eat'res t-an 3ast resin transor!ers.
VPI i!6regnation o 7indings )* e6o:* resins ens'res -ig-
!e3-ani3a, strengt-( 3oo,er o6eration( resistan3e to '.".,ig-t( !oist're
sea,ing against en"iron!enta, -'!idit*( i!6ro"ed eart- tra3king
6ro6erties.
RANGE <
LUDHIANA 41
Transor!ers 7it- rating ro! $00 KVA '6to 4.9 MVA 7it- air nat'ra,
3oo,ing and '6to 5.9 MVA 7it- or3ed air 3oo,ing 7it- 6ri!ar* "o,tages
'6to $9 kV and se3ondar* "o,tages '6to 8.8 kV 3an )e oered.
TPPICAL SPECI;ICATION %
Transor!ers are s6e3iied or 6arti3',ar d't*( to 3'sto!ers
reD'ire!ents. A t*6i3a, s6e3ii3ation is as o,,o7s<
VPI Dr* t*6e( nat'ra,,* air 3oo,ed( 5 6-ase( 90 HE( $$000I155(
3onne3ted to "e3tor gro'6 D*n$$( 7it- $$9

Deg C !a:i!'! 7inding
te!6erat're rise 'sing 3,ass R H R ins',ating !ateria,s. Ta66ing on HV
)* ta66ing ,ink )oards at 4 $I4 F and 9 F ste6s. HV and LV
ter!inations de6end '6on t-e t*6e o d't*( en3,os're and 3'sto!erGs
reD'ire!ents.
CONSTRUCTION <
CORE <
Core is 3onstr'3ted ro! non2aging 3o,d ro,,ed grain oriented stee,
s-eets. Core is treated 7it- -ig- te!6erat're resistant 6aint to 6re"ent
3orrosion at edges o t-e 3ore 6,ates.
=INDINGS<
=indings are o e,e3tro,*ti3 3o66er 3ond'3tor 3o"ered 7it- no!e:
6o,*a!ide 6a6er -a"ing -ig- tensi,e and die,e3tri3 strengt-. Lo7
"o,tage 7indings are t7o ,a*er -e,i3a, t*6e e!6,o*ing n'!)er o stri6s
LUDHIANA 42
in 6ara,,e,. Hig- "o,tage 7indings 3an )e 3rosso"er 3oi,s or dis3 t*6e
3oi,s se6arated ro! ea3- ot-er )* ke*ed radia, s6a3ers.
IMPREGNATION <
Ater 7inding( t-e 3oi,s are i!6regnated )* a 3*3,oa,i6-ati3 e6o:*
resin )* "a3''! 6ress're i!6regnation 6ro3ess. T-is 6ro3ess
ens'res "oid ree i!6regnation i.e. t-e resins 6enetrate and sea, t-e
ins',ating !ateria,s or!ing a 3o!6osite !ass ater 6o,*!eriEation.
T-is gi"es an en3a6s',ated s*ste! 7it- n'!)er o ad"antages.
$. It en-an3es no!e: ins',ating !ateria, )* e,i!inating air 6o3kets
and a,so res',ts in )etter -eat transer.
4. It in3reases t-e !e3-ani3a, strengt- o ins',ation )* 6enetrating a,,
6oro's areas.
5. It 6ro"ides 6rote3tion against !oist're and at!os6-eri3
3onta!inants.
VPI 6ro3ess 3onsists o <
$. Pre-eating < To re!o"e !oist're
4. Va3''! Dr*ing < Moist're and "o,ati,e are re!o"ed.
5. Resin entr* 'nder "a3''!.
1. Va3''! s')!ersion < ;or i!6regnating and i,, in "oids.
9. Press'riEation < ;or or3ing resin into t-e "oids and ins',ation.
8. Draining and transer to o"en.
A. C'ring < Makes 3oi,s into a rigid !ass.
T-e !ain -ardener s*ste!( ado6ted gi"es te!6erat're inde: as -ig-
as 400 Deg. C s'ita),e or 3,ass R H R o6eration.
TAPPINGS <
O 2 3ir3'it ta66ings are 6ro"ided on HV 7indings. Ta6 3-anging is
done )* !eans o o23ir3'it ,inks a33essi),e t-ro'g- t-e o6ening on
LUDHIANA 43
tank side in 3ase o nor!a, "enti,ated 'nits. Use o ta6 3-anging ,inks
e,i!inates an* !o"ing 6arts as against a !an'a,,* o6erated ta6
3-anger.
;ITTINGS <
Standard ittings s'3- as ,iting ,'gs and ro,,ers 7i,, )e 6ro"ided.
;'rt-er ittings !a* )e 6ro"ided to !eet s6e3ia, reD'ire!ents. A
7inding te!6erat're indi3ator I 3ontro,,er a3t'ated )* !eans o
Resistan3e Te!6erat're Dete3tor e!)edded in t-e LV 7indings 3an
)e 6ro"ided. Conta3ts 3an )e 6ro"ided to o6erate a,ar! or tri6 3ir3'its.
ENCLOSURES <
T-e transor!er 3an 7ork 7it-o't en3,os'res. Ho7e"er( or reasons o
saet* reg',ations( it is ad"isa),e to -a"e an en3,os're. An o6en
"enti,ated stee, en3,os're is genera,,* 6ro"ided 7it- !eta, s3reens at
to6 and )otto! or indoor 'se. ;or o'tdoor 'se( a sea,ed t*6e 'nit(
eit-er )reat-ing t*6e or -er!eti3a,,* sea,ed t*6e( 3an )e oered.
U6rating o transor!er 3an )e done )* 6ro"iding ),o7ers 6,a3ed on
t-e )otto! side o t-e en3,os're or "enti,ated 'nits.
TERMINATIONS <
A 3-oi3e o ter!ina,s( 3a),e )o: and )'sd'3ts 3o!6,*ing 7it- re,e"ant
Indian standards is a"ai,a),e to !eet reD'ire!ents. Interna,
3onne3tions take t-e or! o )'s)ar and ,e:i),e 3ond'3tors and are
adeD'ate,* )ra3ed and s'66orted.
TESTING <
LUDHIANA 44
A 3o!6re-ensi"e test seD'en3e is 3arried( o't on a,, transor!ers
!an'a3t'red )* MIs. Cro!6ton Grea"es Ltd. T-e ro'tine test are
3ond'3ted as 6er IS $$$A$ 2 $/@9. Additiona, tests 3an a,so )e 3arried
o't as 6er IS 40482$/AA( i s6e3iied. S'3- tests
$. Te!6erat're rise test )* no ,oad 6,'s s-ort 3ir3'it !et-od.
4. Lig-ting i!6',se test #$.4I90 !i3ro se3 7a"e or!%.
5. Meas're!ent o a3o'sti3 noise ,e"e,.
1. Partia, dis3-arge !eas're!ent.
9. S-ort 3ir3'it test.
SALIENT ;EATURES %
PREMIUM HUALITP IMPREGNATION %
VPI i!6regnation 7it- ,o7 "is3osit* e6o:* resin ens'res t-at ea3-
3orner ? 3re"i3e o transor!er is i,,ed 7it- resinB t-'s !aking a -ig-
D'a,it* transor!er 7it- i!6ro"ed t-er!a,( !e3-ani3a,( die,e3tri3
7it-stand 3a6a)i,ities o t-e transor!er.
LO= PARTIAL DISCHARGE <
Partia, dis3-arges o33'rs 7-en "oids or 3ra3ks are 6resent or o33'rs
in ins',ation s*ste!. Sin3e( VPI ens'res "oid ree i!6regnation( 6artia,
dis3-arge are 6ra3ti3a,,* a)sent. Moreo"er( 'n,ike 3ast 3oi,
transor!ers( t-e 6artia, dis3-arges are not -aEardo's to t-e ,ie o t-e
transor!ers( as e6o:* does not ser"es as ins',ation i.e. transor!er
3an 7it-stand t-e rated i!6',se "o,tage e"en 7it-o't i!6regnation.
NON 2 HPGROSCOPIC <
LUDHIANA 45
Use o e6o:* resin !akes t-e transor!er non2-*gros3o6i3. Hen3e no
dr*ing is reD'ired )eore 3o!!issioning e"en t-o'g- stored or a ,ong
ti!e.
NON2IN;LAMMA>LE <
Transor!er is non2in,a!!a),e )* e,e3tri3 are sin3e !ateria,s 'sed in
t-e 3onstr'3tion are o se,2e:ting'is-ing t*6e and do not 3at3- ire.
OVERLOAD CAPA>ILITP <
T-e transor!er -as )etter o"er,oad 3a6a)i,it* against transient
o"er,oads as en3o'ntered in t-*ristarised s*ste! a66,i3ations. T-is is
d'e to )etter -eat transer as air 6o3kets are i,,ed 7it- e6o:* and d'e
to 'se o no!e: 6a6er or 7indings 7-i3- 3an 7it-stand 440 Deg C
3ontin'o's,*.
TEMPERATURE RISE <
Transor!ers are oered as 3,ass R H R 7it- te!6erat're rise o $$9
Deg C as 6er IS 4048 #6art II%
Transor!ers 3an )e oered 7it- /0 Deg C te!6erat're rise
3orres6onding to 3,ass R ; Q. Ho7e"er( or!er a,ternati"e is o)"io's,*
!ore e3ono!i3a, t-an t-e ,etter.
DESIGN ;LEXI>ILITP ? OPTIMISATION <
It is -ig-,* desira),e ? e3ono!i3a, to o6ti!iEe t-e designs or s6e3ia,
3ondition as 3a6ita,iEation o ,osses( -ig- a!)ient te!6erat're( -ig-er
a,tit'des( s6e3ia, i!6edan3e "a,'es or s*ste! a',t 3oordination
e3ono!i3s and t-e ,ike. Co!6'ter aided o6ti!iEed design gi"es $00
F ,e:i)i,it* 7it-o't additiona, 3ost against 3ast 3oi, transor!er
7-erein 3riti3a,it* o t-er!a, design and e:6ensi"e !o',ds ,i!it t-e
design ,e:i)i,it*.
LUDHIANA 46
COMPACTNESS <
Sin3e transor!ers are design or 3,ass R H R te!6erat're 3,ass( t-e*
are !ore 3o!6a3t and -ig-er in 7eig-t 3o!6ared to 3ast 3oi,
transor!ers.
SHORT CIRCUIT STRENGTH <
E6o:* resin )onding !akes t-e 7indings ro3k -ard. T-is en-an3es t-e
transor!er 3a6a)i,it* against s-ort 3ir3'its.
HIGH RELIA>ILITP %
T-e i!6regnation 6ro3ess !ini!iEes t-e resin 3ra3king d'e to t-er!a,
3*3,ing and !e3-ani3a, stresses. T-e resin 3oating is t-i3k eno'g- to
gi"e !ore en"iron!enta, 6rote3tion )'t t-in eno'g- to !ini!iEe t-e
te!6erat're dierentia, t-ro'g- its t-i3kness. T-is !akes t-e
transor!er "er* re,ia),e.
IMPULSE STRENGTH %
I!6',se strengt- o s'3- transor!er is i!6ro"ed as e6o:* a,ong 7it-
3ond'3tor ins',ation i!6ro"es inter t'rn 7it-stand "a,'es.
Transor!ers 3an )e oered '6to /9 kV )asi3 i!6',se ,e"e, at 6resent.
MAINTENANCE ;REE <
T-is transor!er reD'ires "irt'a,,* !aintenan3e or reg',ar ins6e3tion.
T-e nor!a, -o'se kee6ing o o33asiona, d'sting is eno'g- to ens're
t-e ree air 6assage( as air is t-e 3oo,ing !edi'!.
CROMPTON GERAVES VACUUM PRESSURE RESIGN
IMPREGNATED DRP TPPE TRANS;ORMERS %
LUDHIANA 47
INTRODUCTION <
Cro!6ton gera"es -a"e )een !an'a3t'red Dr* T*6e transor!er or
near,* 40 *ears. T-e transor!ers !ain,* 7ere 3,ass T CU ins',ated
7it- si,i3on "arnis- i!6regnation. Peror!an3e o t-ese transor!ers
is D'ite e:3e,,ent.
In order to '6grade t-e te3-no,og* and to oer a s'6erior transor!er
o t-e 3'sto!er. =e -a"e 3o!e o't o anot-er range o transor!ers
e!6,o*ing a !ore re,ia),e i!6regnation s*ste! 'sing 6o,*ester!ide
resin na!e,* Va3''! Press're I!6regnation S*ste! #VPI%.
T-is VPI i!6regnation s*ste! 7it- 6,*ester!ide resin ens'res -ig-
!e3-ani3a, strengt-( 3oo,er o6eration( i!6ro"ed eart- tra3king
resistan3e and is 'nae3ted )* en"iron!enta, -'!idit* 3onditions.
RANGE O; RATINGS <
Transor!ers 7it- ratings ranging ro! $00 KVA '6to 4.9 MVA 7it-
6ri!ar* "o,tages '6to $9 kV and se3ondar* "o,tages '6to 8.8 kV 3an
)e s'66,ied.
CONSTRUCTION <
Core2T-e 3ore is 3onstr'3ted ro! non2aging 3o,d ro,,ed grain oriented
-ig- 6er!ea)i,it* si,i3on stee,. Internationa, ins',ation is -ig-
te!6erat're resistant. T-e 3o!6,ete 3ore is treated to 6re"ent r'sting
o edges o t-e ,a!ination 7it- -ig- te!6erat're resistant 6aint.
=INDING INSULATION %
T-e 7inding 3ond'3tors are 3o"ered 7it- s6e3ia, t*6e o -eat resistant
6a6er 7it- -ig- tensi,e strengt-. Ot-er !a&or ins',ationGs 3onsist o
g,ass !i3a ),o3ks or a:ia, s6a3ing and e:tr'ded se3tions o 3,ass T HU
LUDHIANA 48
!ateria, or radia, ins',ation. Ho7e"er( transor!er 7it- s6e3iied
te!6erat're rise !a* -a"e an ins',ation s*ste! 'ti,iEing !ateria,s o
an* 3o!)ination #i.e. 3,ass 2 >( ;( ? H% 6ro"ided t-at ea3- !ateria, is
'sed in ,o3ation in t-e transor!er 7-ere t-e te!6erat're does not
e:3eed t-e ,i!it or t-at 3,ass o !ateria,.
IMPREGNATION <
T-e 7indings are "a3''! Press're I!6regnated #VPI% )* s6e3ia,
3,ass THU 6o,*ester!ide resign 7-i3- is e:3e,,ent or rigidit*(
7eat-er6roo( good 3ond'3tor o -eat( Moist're 6roo. As t-is resin
does not or! 6art o !ain ins',ation s*ste!. Partia, dis3-arges 7i,,
not )e -aEardo's to t-e transor!er ,ie. T-is !eans 7e get a,,
ad"antages o resin 3ast Transor!er. O"er and a)o"e( t-ere is no
ee3t o 6artia, dis3-arge.
TAPPINGS <
O23ir3'it ta66ings are 6ro"ided on HV 7inding. Ta6 3-anging is
's'a,,* ee3ted )* !eans o ,inks a33essi),e t-ro'g- t-e o6ening on
tank side.
;ITTINGS <
T-e ittings are genera,,* as 6er IS2$$$A$2$/@9 or standard 'nits.
;'rt-er ittings !a* )e 6ro"ided to !eet s6e3ia, reD'ire!ent. =-ere
te!6erat're indi3ator o6erated )* RTDs 6,a3ed in t-e 7inding 3an )e
s'66,ied. Genera,,*( one r'nning and one stand2)* RTD is 6ro"ided or
t-is 6'r6ose. T-e a':i,iar* 3onta3ts or a,ar! and tri6 3ir3'its 3an )e
6ro"ided or t-is 6'r6ose. T-e a':i,iar* 3onta3ts or a,ar! and tri6
3ir3'its 3an )e 6ro"ided to !eet s6e3ia, reD'ire!ent. =-ere s6e3iied(
a 7inding te!6erat're indi3ator o6erated )* RTDs 6,a3ed in t-e
LUDHIANA 49
7inding 3an )e s'66,ied. Genera,,*( one r'nning and one stand2)*
RTD is 6ro"ided or t-is 6'r6ose. T-e a':i,iar* 3onta3ts or a,ar! and
tri6 3ir3'its 3an )e 6ro"ided on t-e =TI.
ENCLOSURE <
T-e Transor!er 3ore23oi, asse!),* 3o',d )e 'sed 7it-o't an*
en3,os're )* insta,,ing it in a 7e,, "enti,ated 6rote3ted roo!.
;or nor!a, a66,i3ation an o6en "enti,ated t*6e en3,os're 6ro"ided 7it-
!eta, s3reens at to6 and )otto! o t-e en3,os're. It is re3o!!ended
t-at t-e Transor!er 7it- t-is t*6e o en3,os're is insta,,ed in a
reasona),* 7e,, "enti,ated roo!. T-e Transor!er 3an )e designed or
o'tdoor 'se 7it- t-is t*6e o i!6regnation.
T-e transor!er o -ig-er ratings 3o',d a,so )e s'66,ied 7it-
additiona, an 3oo,ing.
TERMINATION <
In 3ase o transor!er 7it- en3,os're a 3-oi3e o ter!ina,s and 3a),e
)o:es 3o!6,*ing 7it- standard is a"ai,a),e to !eet an* reD'ire!ents.
In 3ase o transor!er 7it-o't en3,os're it 7o',d )e ne3essar* or
3'sto!er to !ake arrange!ent o s'ita),e 3a),e sea,ing or HV
3onne3tions and )'s 3onne3tions or LV side.
TESTING <
T-e transor!ers are ',,* tested or ro'tine as 7e,, as t*6e tests as
6er IS $$$A$2$/@9 or re,e"ant >S or IEC as !a* )e reD'ired.
LUDHIANA 50
T-e 6eror!an3e o t-is Transor!er is s'6erior o"er t-e 3on"entiona,
,iD'id i,,ed Transor!ers.
APPLICATION <
At a,, s'3- ,o3ations 7-ere 3on"entiona, oi, i,,ed Transor!ers 6resent
a saet* -aEards. C,ass V ;V ? V HV ins',ated Dr* T*6e Transor!er
are !ost s'ited. So!e o t-ese are
Oi, Reineries
C-e!i3a, P,ants
Marine A66,i3ations
Metro Rai,7a*s
Hig- rise >'i,dings
Stee, P,ants
Hote,s( >ank >'i,dings
Prestigio's >'i,dings
=-ere t-e Transor!er are reD'ired near t-e ,oad 3enter to a3-ie"e
)etter reg',ation and ,o7 distri)'tion ,osses ,ike 3a),e 3ost and
s')station 3ost( C,ass V;V ? VHU ins',ated resin i!6regnated Dr* T*6e
Transor!ers ind t-e a66,i3ation.
ADVANTAGES <
No ire risk
Lig-ter in 7eig-t
Less ,oor area
No to:i3it* 'n,ike s*nt-eti3 ,iD'id i,,ed Transor!ers
Ei3ient noise,ess o6eration
Lo7 !aintenan3e
Energ* ei3ient as tota, ,osses are ,ess.
LUDHIANA 51
Red'3ed insta,,ation 3osts
SPECIAL ADVANTAGES O; RESIN IMPREGNATED
TRANS;ORMERS
1) Partia, dis3-arges are not -aEardo's to t-e nor!a, ,ie e:6e3tan3*
o Transor!er as t-e resin does not a3t as ins',ation o 7indings
'n,ike resin 3ast Transor!ers
2) T-e resin is e:3e,,ent 7eat-er resistant !ateria,( 7-i3- !akes
transor!er s'ita),e or o'tdoor a66,i3ation 7it- e:3e,,ent 7eat-er
resistant 6ro6ert* and i!!'red to -'!idit*.
#) >e3a'se o t-e rigidit* oered )* resin i!6regnation( t-e
transor!er -as )etter s-ort 3ir3'it 7it-stand 3a6a3it*.
4) =it- t-e reD'ent ,oadingI'n,oading o transor!er( 3-an3es o
3ra3k or!ation )e3a'se o dierent 3oei3ient o e:6ansion o !eta,
and se!i so,id is not o33'rring in VPI 6ro3ess as t-i3kness o resin on
3ond'3tor is e7 !i3rons.
$) E,e3tri3it* 6eror!an3e is not de6endent on VPI 6ro3ess as a,,
3ond'3tors et3. ins',ated )* )est ins',ation in t-e 7or,d and -en3e VPI
6ro3ess 3-e3k is not t-at i!6ortant 'n,ike in 3asting 6ro3ess as VPI
6ro3ess is not 'sed as 6ri!ar* ins',ation.
%) Variation in e,e3tri3a, 6eror!an3e as 6er 3'sto!erRs reD'ire!ent is
6ossi),e 'n,ike in 3ast t*6e. It is restri3ted )* !o',d siEe.

LUDHIANA 52

PRE;A>RICATED SU>STATION
Deinition < Prea)ri3ated s')stations are deined as t-e t*6e tested
eD'i6!ent 3o!6rising transor!er( LV (HV S7it3-gear 3onne3tion and
a':i,iar* eD'i6!ent in an en3,os're to s'66,* ,o7 "o,tage energ* ro!
a -ig- "o,tage s*ste!.
LUDHIANA 53
T-e Con3e6t o 6a3kage s')station -as o,,o7ing ad"antages o"er t-e
traditiona, s')station <
$% Pa3kage S')station 3an )e ,o3ated at or "er* near to t-e ,oad
3entre o e,e3tri3a, ,oad red'3ing t-e 3a6ita, 3ost o insta,,ation )*
e,i!inating t-e need or a se6arate s7it3- roo! and res',ting in
7ort-7-i,e sa"ing in 3a),e 3ost.
4% T-ese S')stations 3an 6,a3ed in ,o3ations a33essi),e to 6'),i3 and
ens'res saet* or 6ersons sin3e a,, eD'i6!ent are tota,,* en3,osed.
Prea)ri3ated S')stations are !ore E3ono!i3a, as 3o!6ared to t-e
3on"entiona, S')stations sin3e t-e inter3onne3tions are !ini!'!.
=-i,e Designing and 3onstr'3tion o t-e 6rea)ri3ated s')station t-e
ser"i3e 3ondition ( rated 3-ara3teristi3s ( genera, str'3t'ra,
reD'ire!ents ( test !et-ods et3 ,aid do7n )* Internationa,
E,e3trote3-ni3a, Co!!ision -a"e )een ado6ted.
T-e S')station is )road,* di"ided into 4 )asi3 3ategories<
$% Main Cir3'it< A,, 3ond'3ti"e 6arts o a 6rea)ri3ated s')station
in3,'ded in a 3ir3'it intended to trans!it E,e3tri3a, Energ*.
4% A':i,iar* Cir3'it< A,, 3ond'3ti"e 6arts o a 6rea)ri3ated s')station
in a 3ir3'it to 3ontro, ( !eas're( signa,( reg',ate( i,,'!inate et3.
LUDHIANA 54
Prea)ri3ated S')stations are designed so t-at nor!a, ser"i3e
ins6e3tion and !aintenan3e 3an )e 3arried o't sae,*.
S')station Eart-ing
An Eart-ing 3ond'3tor is 3onne3ted to ea3- 3o!6onent o t-e
6rea)ri3ated s')station ( t-e 3ontin'it* o t-e eart- s*ste! is
ens'red )* taking into a33o'nt t-e "ario's t-er!a, and !e3-ani3a,
stresses 3a'sed )* t-e 3'rrent it !a* -a"e to 3arr*.
Reasons or -a"ing an Eart-ed s*ste! <
W To 6ro"ide a s'i3ient,* ,o7 i!6edan3e to a3i,itate satisa3tor*
6rote3tion o6eration 'nder a',t 3onditions.
W To ens're t-at ,i"ing )eings in t-e "i3init* o s')stations are not
e:6osed to 'nsae 6otentia,s 'nder stead* state or a',t 3onditions.
W To retain s*ste! "o,tages 7it-in reasona),e ,i!its 'nder a',t
3onditions #s'3- as ,ig-tning( s7it3-ing s'rges or inad"ertent 3onta3t
7it- -ig-er "o,tage s*ste!s%( and ens're t-at ins',ation )reakdo7n
"o,tages are not e:3eeded.
W C'sto! and 6ra3ti3e.
W To ,i!it t-e "o,tage to eart- on 3ond'3ti"e !ateria,s 7-i3- en3,ose
e,e3tri3a, 3ond'3tors or eD'i6!ent.
Prote3tion in 6rea)ri3ated s')station and -and,ing o interna, a',ts
LUDHIANA 55
T-e 6rote3tion o 6ersons against t-e -aEardo's 6arts as 7e,, as t-e
6rote3tion o t-e eD'i6!ent against ingress o so,id oreign o)&e3ts
and against 7ater is ne3essar*.
T-e !ain o)&e3ti"e 7-i,e designing and 3onstr'3tion o s')station is
to a"oid interna, ar3s or to ,i!it t-eir d'ration and 3onseD'en3es.
T-e ins',ation )et7een t-e "ario's non s-ie,ded ,i"e 6arts o t-e
3onne3tions )et7een t-e -ig- "o,tage s7it3-gear and 3ontro,gear and
t-e transor!er and t-e "ario's a33essi),e s'ra3e o t-e en3,os're
-a"e 'nder7ent "ario's test "o,tages to a"oid t-e danger o an*
interna, a',t.
INTRODUCTION < It is 6ossi),e in a 6a3kaged s')station to
asse!),e a 7ide "ariet* o a66arat's or 6arti3',ar 6'r6ose in a
!',ti6,i3it* o arrange!ents to in3,'de !ain,* are <
S7it3- ;'se Unit
a% Oi,
)% S;8
3% Air
Ring Main Unit
Tee o#Va3''! Cir3'it >reaker%
Transor!er '6to $.9 MVA
LUDHIANA 56
Air Cir3'it >reaker
Mo',ded Case Cir3'it >reaker
;'se S') Distri)'tion Pane,
Po7er ;a3tor i!6ro"e!ent eD'i6!ent.
T-e 3o!6onents in t-e 6rea)ri3ated s')station 3o!6,* 7it- t-eir
re,e"ant IEC standards.
Genera, C-ara3teristi3s o 850 KVA Prea)ri3ated S')station.
$ Man'a3t'rerGs na!e and 6,a3e o
!an'a3t're
Cro!6ton Grea"es
Ltd (Kan&'r
Marg#M'!)ai%
4 Indian Standard to 7-i3- it
3onir!s
IEC $550
5 O"era,, Di!ension#in !!%
#a66ro:.%
Lengt-
=idt-
Heig-t
4900
$@00
4000
1 Materia, o En3,os're Mi,d Stee, S-eets
9 Degree o 6rote3tion 6ro"ided )*
t-e en3,os're
IP 45
8 T-i3kness o en3,os're s-eet 4!!
A T*6e o Venti,ation Pro"ided )* Means o
Grids.
@ Detai,s o en3,os're 6aint !ateria, Main En3,os're ?
ot-er eD'i6!entGs
6ainted 7it-
'nder3oat o
anti3orrosi"e 6ri!er
LUDHIANA 57
and a 3oat o
)att,es-i6 gra*
ena!e, 6aint.
/ LV side 3onne3tion >'s )ar tr'nking and
AC>
HIGH TENSION S=ITCHGEAR
S=ITCH ;USE UNIT#S;U%
A S7it3- 'se 'nit -as a 'niD'e t-ree 6osition s7it3- 7it- o6ening
and 3,osing o6eration ( it a,so -as a si!6,e inter,o3king s*ste!
6re"enting ro! an* 7rong o6eration.
C,osed < T-is 6osition ass'res t-e 3onne3tion )et7een t-e '66er )'s
)ars and t-e ,o7er 3o!6art!ent.
O6en < T-is 6osition ass'res t-e E,e3tri3a, iso,ation )et7een t-e '66er
)'s )ars and t-e ,o7er 3o!6art!ent
Eart-ed < Eart-ing and a tota, iso,ation saet* are ass'red in t-is
6osition.
Ratings or 'ses or 6rote3tion de6end on t-e o,,o7ing 3riteria B
Ser"i3e Vo,tage
Transor!er Rating
T-er!a, dissi6ation o 'ses
;'se Te3-no,og*.
LUDHIANA 58
Ad"antage o insta,,ing a 'se in t-e s*ste! <
A 'se 'n,ike a 3ir3'it )reaker -as an instantaneo's tri6 !e3-anis! .
A S7it3- ;'se Unit is >road,* Di"ided into 5 >asi3 Categories
a33ording to t-e ins',ation !edi'! <
a% Oi,
)% S;8
3% Air
S',6-'r He:a,oride -as t-e a)i,it* o )etter ar3 D'en3-ing and -as a
-ig-er die,e3tri3 strengt-#At a 6ress're o $./ )ar die,e3tri3 strengt- is
eD'i"a,ent to oi, and )etter and -ig-er 6ress'res%
Ring Min Unit
RMU is a se, 3ontained (tota,,* ins',ated 'nit and 3o!6rises o <
Stain,ess Stee, ( !eta, en3,os're sea,ed or ,ie( 7-i3- gro'6s
toget-er t-e ,i"e 6arts (s7it3- dis3onne3tors( Eart-ing s7it3-( 'se
s7it3- .
Ca),e Co!6art!ent 7it- intera3es or 3onne3tion to t-e net7ork
or to t-e transor!er.
T-e 6eror!an3e 3-ara3teristi3s o)tained )* t-e ring !ain 'nit
!eets t-e deinition o a Tsea,ed 6ress're s*ste!U ,aid do7n in t-e
IEC re3o!!endations.
LUDHIANA 59
VACUUM CIRCUIT >REAKER
Genera, C-ara3teristi3s o VC>
$ Man'a3t'rerGs Na!e Sie!ensI=esting-o'
se
4 ;reD'en3* 90HE
5 Contin'os 3'rrent 3arr*ing
3a6a3it*
400a!6s
1 R'6t'ring 3a6a3it* 40kA
9 Met-od o 3,osing Man'a,
8 Met-od o tri66ing Man'a,ITri6 Coi,
A Nor!a, Vo,tage o o6eration $$kV
@ Making 3a6a3it* 90kA
/ S-ort ti!e 3'rrents 40kA or 5 se3onds
$0 Pro"ision or 3a),e ter!ination Ca),e )o: 7it- g,ands
6ro"ided.
TRANS;ORMER
T-e rating o t-e Distri)'tion Transor!er 3an "ar* '6to
$.9 MVA and !a* )e o oi, t*6e or dr* t*6e 7it- ONAN 3oo,ing.
Re3ent Design 6ra3ti3e and o6ti!iEation o Distri)'tion transor!ers.
$% H'a,it*< A good 6rote3tion and good !aintenan3e s-o',d )e t-ere
to 6reser"e aid and 'ti,iEe a good D'a,it* transor!er.
4% Para!eters o transor!er < Transor!er -a"e a ,arge n'!)er o
"aria),es and t-eir reD'ire!ents dier a great dea,.
LUDHIANA 60
a% Core < D'ring t-e ,ast 1 or 9 de3ades t-e D'a,it* o !agneti3
!ateria, -as )een i!6ro"ed in t-e or! o CRGO
,a!inations.
)% =indings < T-e 7indings 7it- dis3 t*6e are no7 !ade )*
a33'rate,* 3a,3',ating t-e "o,tage distri)'tion 7it- t-e -e,6 o
3o!6'ter aided 6rogra!s. To red'3e t-e edd* ,osses in t-e
7indings ( no7 a da*s t7in 3ond'3tors or 3ontin'o's,*
trans6osed 3ond'3tors are 'sed. T-e -eat generated in t-e
dis3 t*6e 7inding 3an )e i!6ro"ed )* g'ided 6at- to ,o7 in
d'3ts.
3% Ins',ation < T-e ins',ation o t-e 7indings 6,a* an i!6ortant
ro,e. D'ring t-e !an'a3t'ring o 3oi,( it )e3o!es 7eaker d'e to
)ending ( ,iting et3 I!6regnation 7it- ins',ating oi, i!6ro"es t-e
die,e3tri3 strengt- o t-e 6a6er.
Using oi, 3o!6ati),e i!6regnates ,ike "arnis- or resin
i!6ro"es )ot- t-e die,e3tri3 and 6-*si3a, strengt-.
d% Man'a3t'ring Pro3ess < D'ring t-e !an'a3t'ring 6ro3ess ( t-e
treat!ent o ins',ating !ateria,s and !inera, oi, is "er* i!6ortant .
To dr* t-e transor!er 7it- 3ore and 3oi, asse!),* "a3''!
o"en is 'sed 7-i3- a)sor)s t-e !oist're ro! t-e 7indings.
LUDHIANA 61
LO= VOLTAGE S=ITCHGEAR
T-e in3o!ing 3onne3tion ro! t-e LV =inding o t-e transor!er
"ia ;,e:i),e 3o66er )'s)ars.
T-is 3onne3tion 7i,, )e 6ro"ided 7it- re!o"a),e ,inks to a3i,itate
t-e iso,ation o eit-er t-e transor!er or LV distri)'tion
s7it3-gear.
T-e ,o7 "o,tage S7it3-gear 3o!6art!ent 3o!6rises o one or
!ore o t-e o,,o7ing 3o!6onents <

$% Air Cir3'it >reaker
4% Mo',ded Case Cir3'it >reaker#s%
5% S7it3- ;'se 'nit
Sensors
1% Meas'ring De"i3es ,ike A!!eter(Vo,t!eter et3.
9% Ot-er A33essories
S6e3ia, ;eat'res o Air Cir3'it >reaker <
$% A,, Contro, A33essories A33essi),e ro! t-e ront.
4% No ad&'st!ents ater Mo'nting a33essories.
5% TRead* to 3,oseU inter,o3k e,i!inates !a,o6eration d'e to
'ndesired 3,osing o inter,o3ked )reakers.
LUDHIANA 62
1% Conta3t Erosion indi3ator i!6ro"es '6ti!e.
Genera, C-ara3teristi3s ;or Air Cir3'it >reaker <
$ Man'a3t'rerGs Na!e Sie!ens I Re6'ted
4 Rated C'rrent U6to 4000A
5 Rated o6erationa, "o,tage U6to 8/0V
1 Rated S-ort Cir3'it !aking
3a6a3it*
$$0kA
9 Rated S-ort Cir3'it >reaking
Ca6a3it*
90kA
8 Rated S-ort Ti!e =it-stand
C'rrents or $ se3onds
90kA
A Per!issi),e a!)ient te!6erat're
or o6eration
240 to XA0
@ Degree o 6rote3tion IP 91
/ Di!ensions#in !!% #a66ro:.%
Heig-t <
=idt- <
De6t- <
1@9
140
1A0
Mo',ded Case Cir3'it >reaker <
T-ese are designed or 3ir3'it 6rote3tion o ,o7 Vo,tage distri)'tion
s*ste!.
T-e MCC> Pro"ides o"er,oad and S-ort Cir3'it 6rote3tion<
MCC> Co!6rises o <
a% S7it3-ing Me3-anis!
LUDHIANA 63
)% Conta3t S*ste!
3% Ar3 E:ting'is-ing de"i3e and
d% Tri66ing 'nit ( a,, 3ontained in a !o',ded 3ase 3o"er.
T-e ins',ating 3ase and 3o"er are !ade o -ig- strengt- ( -eat
resistant ( ,a!e retardant resin )o'nded t-er!o2setting !ateria,.
S6e3ia, ;eat'res o MCC> <
a% Ad&'sta),eI ;ront a33essi),e t-er!a, and !agneti3 setting
)% MCC> is a 5 6o,e 7it- S7it3-ed Ne'tra, Version.
3% T-er!a, Setting or O"er,oad is Ad&'sta),e o rated 3'rrent and
!agneti3 setting or s-ort 3ir3'it ad&'sta),e too.
T-e CTGs 'sed 7it-in t-e 'nit are s6e3ii3a,,* designed or 'se in
3on&'n3tion 7it- t-e 6rote3tion re,a* and or t-e rating o t-e
transor!er .
T-e o'tgoing Distri)'tion 'nit 3ontains t-e o,,o7ing e,e!ents <
a% O'tgoing eeders eD'i66ed 7it- 'ses
)% An MCC> to s'66,* to 3a6a3itor )ank

LUDHIANA 64

PROCECT REPORT ON PRE;A>RICATED SU>STATIONS.
850 KVA $$KVI155V PRE;A>RICATEDIUNITISED SU>STATION
Prea)ri3ated S')station is a t*6e tested eD'i6!ent 'sed to transer
energ* ro! a -ig- "o,tage s*ste! to a ,o7 "o,tage s*ste! 7it- no
3-ange in reD'en3* )'t 7it- a 3-ange in "o,tage and 3'rrent.
T-e Prea)ri3ated S')stations 3o!6rises o a transor!er( HV
S7it3-gear( LV S7it3-gear 3onne3tions and A':i,iar* eD'i6!ent in an
en3,os're to s'66,* ,o7 "o,tage energ* ro! a -ig- "o,tage s*ste!.
NEED ;OR A PROCECT ON PRE;A>RICATED SU>STATION IN
CROMPTON GREAVES Ltd.
LUDHIANA 65
5% Pa3kage S')station 3an )e ,o3ated at or "er* near to t-e ,oad
3entre o e,e3tri3a, ,oad red'3ing t-e 3a6ita, 3ost o insta,,ation )*
e,i!inating t-e need or a se6arate s7it3- roo! and res',ting in
7ort-7-i,e sa"ing in 3a),e 3ost.
1% T-ese S')stations 3an 6,a3ed in ,o3ations a33essi),e to 6'),i3 and
ens'res saet* or 6ersons sin3e a,, eD'i6!ent are tota,,* en3,osed.
9% Prea)ri3ated S')stations are !ore E3ono!i3a, as 3o!6ared to t-e
3on"entiona, S')stations sin3e t-e inter3onne3tions are !ini!'!.
8% >e3a'se t-ese 'nits are ',,* a3tor* asse!),ed 'nits( !o'nting on
t-e site26re6ared o'ndation is eas*.
A% Si!6,iied 3ontra3t'a, 6ro3ed'res )* sing,e so'r3ing o t-e
3o!6,ete s')station.
@% A Hig- degree o saet* and o6erationa, re,ia)i,it* are a3-ie"ed )*
3are',,* se,e3ting t-e asso3iated HT ? LT S7it3-gear a,ong 7it-
t-e dr* t*6e 3ast resin transor!er 7it- s'ita),e t-*ristors and
3ontro,,ers or 6rote3ting t-e transor!er ro! o"er,oading.
/% T-e s')station 3an )e 'sed or eeding 6o7er in o6en 3ast !ines(
3onstr'3tion sites ( !etro 3ities et3.
MAIN COMPONENTS O; THE PRE;A>RICATED SU>STATION
a% Transor!er< A 850 KVA( $$KV I 155 V D*n$$(ONAN 7it- o Load
ta6 3-anging s7it3- andstandard ittings as 6er ISIIEC standards.
LUDHIANA 66
T-e transor!er -as HT ;,ange 7it- )'s-ings to ) 3o'6,ed dire3t,*
7it- t-e o'tgoing o t-e HT 6ane, and LT ;,ange 7it- t-e in3o!ing
o t-e LT 6ane,. T-e transor!er 3an eit-er )e oi, i!!ersed t*6e or
Dr* t*6e 7it- No!e: ins',ation.
)% Hig- Tension S7it3-gear< T-e in3o!ing o t-e HT Pane, is 6ro"ided
7it- t-e 6,'g so3ket or 3a),e )o: and ed in t-e ring !ain 'nit
3o!6,ete 7it- CT( PT( S7it3- ;'se 'nit( Re,a*s( !eas'ring
De"i3es( et3. T-e o'tdoor 6ane, is dire3t,* 3o'6,ed 7it- HT ,ange
o t-e transor!er 7it- t-e 3o66er )'s )ars.
3% Lo7 Tension S7it3-gear< LT Pane, is o'tdoor t*6e( 3o!6rising o
one or !ore air 3ir3'it )reaker or MCC> eit-er in sing,e or )oard
or!ation s'ita),e or a s*ste! "o,tage o 1$9 V( 5 6-ase ( 90 CIS.
In3o!ing o t-e LT 6ane, is dire3t,* 3o'6,ed 7it- t-e LT ;,ange o
t-e transor!er. T-e o'tgoing is eit-er 3a),e )o: or 6,'g ? so3ket
arrange!ent or eeding 6o7er to LT ED'i6!ent.
LAPOUT O; A PRE;A>RICATED SU>STATION.
LUDHIANA 67
Genera, C-ara3teristi3s o 850 KVA Prea)ri3ated S')station.
$ Man'a3t'rerGs na!e and 6,a3e o
!an'a3t're
Cro!6ton Grea"es
Ltd (Kan&'r
Marg#M'!)ai%
4 Indian Standard to 7-i3- it
3onir!s
IEC $550
5 O"era,, Di!ension#in !!%
#a66ro:.%
Lengt-
=idt-
Heig-t
4900
$@00
4000
1 Materia, o En3,os're Mi,d Stee, S-eets
9 Degree o 6rote3tion 6ro"ided )*
t-e en3,os're
IP 45
8 T-i3kness o en3,os're s-eet 4!!
A T*6e o Venti,ation Pro"ided )* Means o
Grids.
@ Detai,s o en3,os're 6aint !ateria, Main En3,os're ?
ot-er eD'i6!entGs
6ainted 7it-
LUDHIANA 68
'nder3oat o
anti3orrosi"e 6ri!er
and a 3oat o
)att,es-i6 gra*
ena!e, 6aint.
/ LV side 3onne3tion >'s )ar tr'nking and
AC>
Sing,e Line Diagra! or a 850KVA $$KVI155V Unitised S')station.
LUDHIANA 69
CALCULATIONS INVOLVED IN THE DESIGN O; UNITISED
SU>STATION.
Gi"en Rating o t-e S')station.
Po7er Rating< 850KVA
HV Vo,tage < $$KV
LV Vo,tage < 155V
Se,e3tion o t-e Ring Main UnitGs Ratings
HV C'rrent< IL850I#$.A54:$$%
L55.08 a!6s.
$ Man'a3t'rerGs Na!e Cro!6ton Grea"es Ltd(
Na-sik
4 Ser"i3e ;reD'en3* 90HE
5 Rated "o,tage $9.9kV
1 Ser"i3e nor!a, 3'rrent 850A!6s
9 ;a',t Le"e, at $$KV 590MVA
8 I!6',se =it-stand Vo,tage $$0kV#6eak%
A >reaking 3'rrent .85kA
@ Making 3'rrent 99kA
/ S-ort ti!e 3'rrents 4$./kA or 5 se3onds.
Design Pro3ed're o a 850KVA ($$ kV I155V ONAN Transor!er.
LUDHIANA 70
Gi"en >asi3 in6't
$% Po7er rating 850KVA
4% Non A'to transor!er
5% Rated Vo,tage Ratio $$kVI155V
1% ;reD'en3* 90HE
9% Ve3tor Gro'6 D*n$$
8% Ta6 range #X9F to29F% in ste6s o#4.9F%
A% I!6eden3e 1.A9F
@% No Load Loss $$00#!a:%
/% Load ,oss @000#!a:%
Looking at so!e 6re"io's designs and t-e "a,'e o t-e no ,oad ,oss
Se,e3ting > as $.ATes,a
Core dia!eter.L1:#KVA%
L40.013!
L400.1!!
No7 t-e area o t-e 3ore L#5.$1Kd/4)K'ti,iEation a3tor
L4A$.$4 3!.
(here utilization factor is 0.86)
No7 VITL1.11::>:A
L1.11:90:$.A:4A$.1:0.000$0
LUDHIANA 71
L$0.45
LV t'rns LLV 6-ase "o,tageI #VIT%
L#155I$.A54%I$0.45
L41.15
L41#a66ro:%
No7 or 41 LV T'rns Re"ised VITL#155I$.A54%I41
L$0.1$
Ca,3',ating t-e a3t'a, >( >L#VIT%I#1.11:90:.04A$%
L$.A5 Tes,a
No7 Ca,3',ating HV Prin3i6a, Ta6 t'rns L#HV 6-ase "o,tage%IA3t'a,
VIT
L$$000I$0.1$
L$098.8
L$098#a66ro:%#Taking t-e e"en
nos. o t'rns%
Ca,3',ating t'rnsIta6 3ir3'itL#4.9I$00%:$098
L48#a66ro:%
No7 3a,3',ating t-e ta6 t'rns <
a% Ma: ta6 t'rn $098X94L$$0@
)% $098X48L$0@4
3% Prin3i6a, ta6 t'rn $098
d% $098248L$050
LUDHIANA 72
e%Min ta6 t'rn $098294L$001
HIGH VOLTAGE CALCULATIONS
Line 3'rrentL#850%I#$.A54:$$%
L55.08 a!6s
6-ase 3'rrentL#55.05%I$.A54#De,ta 3onne3ted HV%
L$/.0/a!6s.
Se,e3ting t-e ,a*er t*6e o 7inding.
Nos o 3oi,s + t-ree
T'rns N 3oi, + $$0@
Nos o La*ers +/
T'rns N La*er2 $45.$$$$$
Se,e3ted t'rns N ,a*er2$41
#t-erore dro6 t'rn 6er ,a*er L .@@@@%
t-ereore tota, dro6 in @ ,a*ersLA.$$$$$
Hen3e tota, t'rns in ,ast ,a*erL$45.$$$$2A.$$$$$
L$$8
Ins',ation )et7een t-e ,a*ersL0.9!! 6a6er )et7een a,, 1.@!! )N 7
82A ,a*er
Se,e3tion o t-e HV 3ond'3tor
Ca,3',ation o t-e 3ond'3tor 7idt-
LUDHIANA 73
Se,e3ting t-e 3ond'3tor -eig-t as 190 !! #ro! 6re"io's designs and
a66ro:i!ations%
T-ereore < 190L$41:#=X0.501@:4%
=L5.04 !!#7it- 6a6er 3o"ering%
No7 se,e3ting t-e 3'rrent densit* as 5.$AI!!
No7 3ond'3tor t-i3kness L$/.0/I#5.04:5.$%
L4.01 !!#7it- 6a6er 3o"ering%
Radia, t-i3knessL/:4.01 X A:.9:./ X$:1.@:./
L45.8A
L41 !!#a66ro:%
Mean t'rn o HV in !trsL0.4/09:5.$1
Lengt- #!trs% L!ean t'rns : No o 7o'nd ,egs : no o t'rns
6er ,eg
L0.4/09:5.$1 : 5 : $$0@
L5054#!a:%
Ca,3',ating t-e 7eig-t o t-e 7inding
=tL5054 : 8.$5 : @.@/ : 0.000$0
L$89.45 Kg.
Densit* o 3o66er L @.@/: .000$0KgI!2!!
Calculation of resistance
R= ,IA
LUDHIANA 74
L.04$$#Resisti"it* o 3o66er at A9 deg 3%
RL.04$$ : 5054I#8.$5%
L $0.11 o-!
Ca,3',ating t-e I&R Losses L 5@0$=atts.
LO= VOLTAGE CALCULATIONS
LV ,ine 3'rrentL#850:$000%I$.A54:155
L@10.09 a!6s
Nos o 3oi,s $:5
Coi, no $
T'rns I 3oi, 41
Nos o La*ers 4
T'rns 6er ,a*er $$.A9 $4.49
#T-ere is .49 t'rn ,ess in t-e irst ,a*er and .49 t'rns greater in t-e
se3ond ,a*er%
Se,e3tion o t-e 3ond'3tor
No7 t-e a:ia, ,engt- se,e3ted L190 !!
190L$4.49#:X.@%
:L10#t-is re6resents a "er* ,arge 7idt-%
Se,e3ting 5 3ond'3tors a:ia,,*
LUDHIANA 75
190 L $4.49:5#:X.@%
: L $$.1!!#7it- 6a3king%
Se,e3ting t-e 3'rrent densit* as 5.9@ ro! 6re"io's designs and
a66ro:i!ations
Cond'3tor t-i3kness #@10.09%I#5.9@:5:$$.1%
L8.@8!!
No7 'sing 4 3ond'3tors radia,,*
Cond'3tor t-i3knessL8.@8I4
L5.15!!
Hen3e ee3ti"e 3ond'3tor AreaL8.@8:51.4
L451.84#3o"ered area%
no7 Mean LV t'rns L 0.448@:5.$1
Lengt- LMean LV T'rns : No o 3oi,s 7o'nd : t'rns 6er 3oi,
L .448@:5.$1:41
L 9$.4A!
Radia, t-i3kness o t-e LV =indingL8.@8:4X5.4X4
L$/!!
=eig-t o t-e LV 7inding
=tL9$.5 : 451.84 : @.@/ : .00$0
L$0A Kg.
LUDHIANA 76
R= ,IA
L.04$$#Resisti"it* o 3o66er at A9 deg 3%
Resistan3e L. 04$$ : 9$.4AI451.84
L .0018
I &R Loss L 5418.$18 =atts.
Hen3e tota, I &R Loss in t-e HV and t-e LV =indings o t-e transor!er
L5418.$18X 5@0$
LA01A.$18=atts
Ca,3',ations o t-e Edd* Losses
;or A33'rate Edd* 3'rrent ,oss 7e 'se t-e Edd* ,oss 6rogra!!e.
KL4.$5:$0#29% : #$.A@:N:I I L% : #$I5%:# HEI90%
L .019$9
Edd* Loss Ca,3',ation
LV Edd* ,oss L LV T-i3kness x Mass x K
= 0. x !0A : .019$9
L.151A/ K=
L151.A/ =atts
HV Edd* ,oss L HV t-i3kness x Mass x K
= ."04 x !6#." x .04#!#
= .!046! K$
= !0.46! $atts
LUDHIANA 77
%herefore total e&&' loss = !0.46!(44.)*
=)4#."# $atts
hence the total +oa& loss of the transfor,er &esi-ne&
%otal +oss = )4#."# ( )04).!46
= ))*".*6 $atts
Calculation of the ./ loa& +oss of the transfor,er
$ei-ht of the core = 6#4 0-(a11rox)
2ence no loa& loss = !.48 x 6#4
=*68 $atts.
(3here !.48 is $atts/K- 45aluate& fro, the -ra1h)
.o3 calculatin- the o5erall &ia,eter
Core &ia,eter "00
Core6 +7 #
"0#
+7 Ra&ial (!*,,) ""4
"4
276 +7 Clearance !0.4
"#.4
27 Ra&ial("4,,) ")).4
0!.4
8h68h clearance 4"
LUDHIANA 78
4.4!
2ence the total &ia,eter =4.4! ,,
9,1e&ence calculations of the transfor,er
:,1ere turns &ia-ra,
LUDHIANA 79
Calculatin- the area of :% &ia-ra,
; = LV radia, : LV !ean dia!eter :#a (< ( a< )/
( 2ilo ra&ial x hilo ,ean &ia,eter x #a (< ( a< )/
(27 ra&ial x 27 ,ean &ia,eter x #a (< ( a< )/
=6".6*) c,
= i,1e&ance = 4>"#=
CALCULATION O; THE LO= TENSION S=ITCHGEAR
SPECI;ICATIONS.
LINE CURRENT L @10.01 a!6s
Hen3e t-e Air Cir3'it >reaker se,e3ted is o $000 a!6s and is o o'r
6o,es
T-e o'tgoing o t-e AC> is ed into t-e in3o!ing o t-e o'r !o',ded
3ase 3ir3'it )reakers .
Ratings o t-e MCC>
$% 5 MCC>Gs o t-e rating 490A!6s
4% $ MCC> o t-e rating $00A!6s.
Meas'ring and !etering de"i3es are 6ro6er,* in3or6orated 7it- t-e
3ir3'it )reaker.
LUDHIANA 80
HT S=ITCHGEAR
Ring !ain 'nit
Oi, >ased( Ring Main Unit.
Ring Main 'nit is a 3o!6a3t 'nit 3o!)ining a,, HV 'n3tiona, 'nits to
ena),e 3onne3tion (s'66,* and 6rote3tion o one or t7o transor!ers
on an o6en ring or radia, net7ork.
>* a 'se2s7it3- 3o!)ination .

T-e >asi3 ring !ain 'nit 3o!6rises t7o#ring% oi, s7it3-es in a a
3o!!on 3-a!)er at t-e to6. and one 'sed #tee o% oi, s7it3- in a
se6arate 3-a!)er 'nderneat-.
LUDHIANA 81
>ot- 3-a!)ers are oi, i,,ed and itted 7it- 7eat-er 3o"ers 7-i3- are
3,osed 7-en t-e 'nit is in ser"i3e.
T-is 'nit 3an )e dire3t,* s'66orted on t-e transor!er.
Oi, S7it3-es #ring 3ir3'it %
Ea3- o t-e t7o s7it3-es is a sing,e )reak t-ree 6osition t*6e
+QOnG (GOG ( QEart-G . Eit-er s7it3- 3an )e o6erated inde6endent,* o
t-e ot-er.
LUDHIANA 82
;'se S7it3-#tee o 3ir3'it%
T-is is a do'),e +)reak 'nit a,so o t-ree 6osition design + QOnG( QOG (
QEart-G. T-e QonG to QoG seD'en3e is a3-ie"ed eit-er )* !an'a, tri66ing
at t-e !e3-anis! or )* t-e a3tion o an* o t-e 'se ,ink striker 6ins as
t-e res',t o a ),o7n 'se.
O6ening t-e 'se a33ess 3o"er#7-i3- 3an )e done on,* 7it- t-e s7it3-
in t-e QoG or QEart-G 6osition% a'to!ati3a,,* dri"es t-e 'se 3arrier
3onta3ts ro! t-e ser"i3e to t-e iso,ated 6osition # ee3ti"e,* do'),e
dis3onne3ting t-e 'ses% ro! 7-i3- 6osition t-e 3arrier 3an )e raised
to e:6ose t-e 'ses or re6,a3e!ent.
S7it3- o6eration in t-e Ring Main Unit.
T-e ring s7it3-es are o6erated )* t-e !e3-anis!s at t-e ront o t-e
'nitB t-e 'se s7it3- is a3ti"ated )* a !e3-anis! !entioned on t-e
'nit. A -and,e (-o'sed readi,* at t-e rig-t -and side is 'sed or a,,
o6erations( s*!)o,s on t-e -') o t-e -and,e indi3ate t-e a66,i3ation.
A,, t-e s7it3-es o6erate 'nder oi,.
Inter,o3ks
Positi"e saet* inter,o3ks are in3or6orated.
A s7it3- 3annot )e dire3t,* !o"ed ro! QOnG to QEart-G 6osition or
ro! QEart-G to QOnG 6osition 7it-o't 6a'sing at t-e !id27a* QOG
6osition.
LUDHIANA 83
T-e test a33ess 3o"er o a ring s7it3- 3annot )e o6ened ( and t-e
test 6,'gs 3annot )e inserted or 7it-dra7n 'n,ess t-e s7it3-( is in
t-e QEart-G 6osition.
A ring s7it3- 3annot )e s7it3-ed to QOnG i a 'se -as ),o7n.#T-is
o6eration is 6re"ented )* t-e intereren3e 3reated )* t-e 6rotr'ding
striker 6in.%
Pad,o3ks
An* o t-e s7it3-es 3an )e 6ad,o3ked in t-e QOnG QO G or QEart-G
Position.
T-e 6ad,o3k ,'gs are integra, eat'res o t-e s7it3- !e3-anis!s B t-e
iss'e o 6ad,o3k ke*s on,* to a't-enti3ated 6ersonne, ens'res
se3'rit*.
Eart-ing
A,, 'nits are 6ro"ided 7it- e:terna, st'ds or Eart-ing 3onne3tions.
Ta),e o E,e3tri3a, 3-ara3teristi3s o a Ring Main Unit
$ Rated Vo,tage $4kV
4 Ser"i3e 3'rrent nor!a, 850A
5 ;a',t ,e"e,#at $$kV% 590MVA
1 I!6',se 7it-stand "o,tage $$0kV#6eak%
9 >reaking 3a6a3it* 0.85kA
8 S-ort ti!e 3'rrents 4$./kA or 5 se3onds.
T*6es o ring Main 'nit
LUDHIANA 84
a% Non E:tensi),e t*6e
)% E:tensi),e t*6e
O6erating Me3-anis! o t-e Ring !ain Unit
A% O6erating t-e OIL S=ITCHES.
a% O;; to ON<2P,a3e t-e se,e3tor in t-e ONIO;; 6osition( insert t-e
-and,e at E and !o"e '67ards to 6osition ;.
LUDHIANA 85
)% ON to O;;<2 =it- t-e se,e3tor set at ONIO;;. Insert t-e -and,e at ;
and Mo"e it '67ards to 6osition E.
3% ON to EARTH<2 P,a3e t-e se,e3tor in t-e EARTH 6osition ( Insert
t-e -and,e at G and !o"e it do7n7ards to 6osition H.
d% EARTH to O;;<2 =it- t-e se,e3tor in t-e EARTH 6osition. Insert t-e
-and,e at H and Mo"e it '67ards to 6osition G.
> O6reating t-e ;USE S=ITCHES
a% O;; to ON<2 Insert t-e -and,e at > and !o"e it do7n7ards to
6osition A.
)% TRIPPING to O;;<2 Press do7n7ards t-e E:terna, ,e"er !arked
QPress to Tri6G.
3% O;; to EARTH<2 Insert t-e -and,e at CV on t-e ,o7er s-at and
!o"e it do7n7ards to 6osition D.#Note t-at or ear,ier designs o
'nit t-e resetting o6eration is ne3essar*%
d% EARTH to O;;<2insert t-e -and,e at D and !o"e it '67ards to
6osition C.
;'se re6,a3e!ent<2
;'se !an'a3t'rerGs re3o!!ended t-at a,, t-ree 'se2,inks are
re6,a3ed ater a a',t o6eration e"en t-o'g- on,* one 'se !a* -a"e
),o7n.
LUDHIANA 86
$% P't t-e 'se s7it3- in t-e O;; or EARTH 6osition and o6en t-e
a33ess 3o"er. T-e 'ses are no7 3o!6,ete,* iso,ated.
4% Gri6 t-e to6 o t-e 'se 3arrier !o',ding and ,it it to t-e irst ,at3-ed
6osition. Lit and ,ater ,o7er% t-e 3arrier s,o7,* to a,,o7 t-e tra66ed
oi, to drain gent,* 7it-o't s6,as-ing.
5% Lit t-e 3arrier to t-e se3ond( ',,* raised 6osition. T-e 'ses are
no7 ree,* a33essi),e.
1% Undo t-e t7o i:ing 3,a!6s to re,ease t-e o,d 'se. =-en inserting
and re3,a!6ing t-e ne7 'ses ens're t-at it sits ir!,* on t-e
)otto! 3ross s'66ort and -as t-e strike 6in end '66er!ost.
9% Re,ease t-e 3at3-es and gent,* ,o7er t-e 3arrier to itGs ',, ,o7est
6osition I t-e 3arrier #or t-e 'ses%are ,et too -ig- in t-e g'ide
s*ste! t-e tri6 )ar !a* )e o',ed2rendering t-e tri6 ino6erati"e.
8% C,ose and )o,t t-e a33ess 3o"er and a3t'ate t-e s7it3- !an'a,,* to
3onir! 3orre3t o6eration.
TRANSFORMER
T-e transor!er 'sed in t-e 6a3kaged s')station is o t-e rating o
850 KVA 7it- t-e HV Vo,tage o $$kV and t-e LV Vo,tage as 155V.
Vario's Ca,3',ations in"o,"ed in t-e design o t-e s')station are
s-o7n a)o"e .
LUDHIANA 87
MODEL LINE DIAGRAM AND DESCRIPTION O; ;OR THE
TRANS;ORMER MANU;ACTURE.
T-e !o!ent a 3'sto!er order is re3ei"ed 6,anning 7ing -as to i,, t-e
dateI 7eeks de6ending '6on transor!er ti!e 3*3,e in stage
3o!6,etion 3o,'!ns#re3tang',ar ),anks% o t-e ,o7 diagra! )*
7orking )a3k i.e starting ro! dis6at3- to )a3k7ards ater t-ese
datesI7eeks are 3-e3ked and a66ro"ed )* t-e 6rod'3tion 3-ie(
3o6ies o t-ese ,o7 diagra! d',* i,,ed or ea3- transor!er
se6arate,* s-o',d )e sent to design ( !ateria, !anage!ent #6'r3-ase%
( a,, eeders asse!),* se3tions o t-e 6rod'3tion area 3o!!er3ia, and
-ead o t-e 6rod'3t.
A 7eeke,* re"ie7 !eeting 7it- a,, a)o"e des3ri6ti"es s-o',d )e -e,d
and !onitored or itGs a3-ie"e!ent.
A,, des3ri6ti"es s-o',d o,,o7 sa!e dates s6e3iied on t-e ,o7
diagra! to a"oid 3on'sions.
;or so!e 'na"oida),e reasons i an* a3ti"it* is getting de,a*ed
a)nor!a,,* ( ot-er 3onne3ted a3ti"ities 3an )e s,o7ed#not sto66ed % to
a"oid !is!at3- in 6rod'3tion.
It is an art to 6rod'3e a tai,or !ade transor!er 7it- !ini!'!
in"entor* and 7it-o't an* !is!at3- to a3-ie"e s-ort 3*3,e de,i"eries
7-i3- is t-e 6resent 3'sto!er de!and .
LUDHIANA 88
In t-e 6resent s3enario 6 o transor!er )'siness ( !eeting s-ort
de,i"eries 7i,, )e a great )oo!.
;,o7 diagra! 7i,, )e o !'3- 'se i it is re,igio's,* o,,o7ed.
ENERGP E;;ICIENT TRANS;ORMERS.
A Co!6arison )et7een CRGO#3o,d Ro,,ed Grain Oriented% M1 ?
A!or6-o's Core Transor!ers.
$% A!or6-o's is -aEardo's to t-e
skin
CRGO is !ore 'ser riend,*
4% No Load ,osses are ,o7 No ,oad ,osses are -ig-
5% ;or sa!e 3a6a3it* ( !ateria, Materia, 'sed is ,ess as design
LUDHIANA 89
'sed is !ore )e3a'se sat'ration
,': densit* is $.5 Tes,a
,': densit* or design.
1% It reD'ires !ore initia, 3ost (
-en3e !ore in"est!ent and
interest )'rden
Initia, in"est!ent is Lo7
9% ;or sa!e 6ri3e (ei3ient on,*
7-en ,oad is on t-e ,o7er side. I
t-e transor!er is ,oaded
3ontino's,* to itGs rated 3a6a3it*it
is not ei3ient.
Less ei3ient 7-en transor!er
eeding ,o7 ,oad or t-er is no ,oad
on t-e transor!er.
8% T-e 7indings are s'3- as
-e,i3a,I Dis3 are dii3',t to !ake
as 3oi,s are re3tang',ar
An* t*6e o 7indings 3onstr'3tion
is 6ossi),e
A% T-e7 s-ort 3ir3'it or3es are
not 3ir3',ar as 7inding are not
3ir3',ar -en3e !ore 6rone to ai,
d'ring s-ot 3ir3'it test
T-e radi3a, or3es are 'nior! .
=indings are 3ir3',arand -en3e
!ore re,ia),e.
@% A -ig- ski,, is reD'ired o
!aking 7indings.
Lesser ski,, is reD'ired.
/% Materia, is )ritt,e ? d'ring
asse!),* !eta,,i3 3an a,, into
7inding ( re 'se is not 6ossi),e
Materia, is ,e:i),e and 3an )e re2
'sed.
$0% C-ange in ,osses d'e to air
ga6 is "er* -ig- ( so!e ti!es it is
o)ser"ed t-at d'ring
trans6ortation (,osses are
in3reased.
Ee3t o t-e air ga6 is "er* ,o7.
Core 3onstr'3tion de6ends on "ario's a3tors as "o,tage ( 3'rrent and
reD'en3*. SiEe ,i!itations and 3onstr'3tion 3osts are a,so a3tors to
LUDHIANA 90
)e 3onsidered. Co!!on,* 'sed 3ore !ateria,s are ot iron and stee,.
Air 3ored transor!ers are 'sed 7-en t-e "o,tage so'r3e -as -ig-
reD'en3*( a)o"e 40kHE ( ot-er7ise 7e 'se iron 3ore.
T-e 3ores -a"e &oints and ste6 ,a6 3onstr'3tion ( 7-i3- res',ts in
a"oiding ,': ringing at &oints and red'3ing no2,oad 3'rrents )* 10F
and no ,oad ,osses )* $02$9F res6e3ti"e,*.
Transor!er Para!eters.
One o t-e !ost i!6ortant 6ara!eter or t-e transor!er is itGs F
i!6edan3e.
FS denotes t-e "o,tage dro6 as F o t-e rated "o,tage a3ross t-e
transor!er
7-en it s'66,ies t-e rated ,oad. ;or eg ($0F i!6edan3e !eans $0F
o t-e rated
"o,tage 7i,, dro6 a3ross t-e transor!er 7-en it is s'66,*ing rated
,oad. T-e
-ig-er t-e F S ( t-e ,o7er 7i,, )e t-e a',t 3'rrent. It res',ts in
reD'ire!ent o
E,e3tri3a, eD'i6!ent "iE Cir3'it )reakers ( 3a),es et3 o ,o7er rating.
At t-e sa!e
ti!e -ig-er FS res',ts in 6oor reg',ation at t-e ,oad end )e3a'se o
!ore
LUDHIANA 91
"o,tage dro6 in t-e transor!er itse,. =e t-ereore !'st o6ti!iEe F S
o t-e
transor!er.

T-e ;a',t ,e"e, a3-ie"es a sat'ration ,e"e, ater 3ertain FS
in3rease and 'rt-er F S res',ts in 6oor reg',ation at t-e ,oad end
)e3a'se o !ore "o,tage dro6 in t-e transor!er itse,.
LO= VOLTAGE S=ITCHGEAR
A Main in3o!ing Air Cir3'it >reaker.
LUDHIANA 92
T-e o'tgoing o t-e transor!er is ed in to t-e in3o!ing 6ane, o t-e
,o7 "o,tage 3')i3,e.
SPECI;ICATIONS O; AIR CIRCUIT >REAKER
$ O6erating Vo,tage 1$9V28/0V AC
4 Ins',ation Vo,tage $000V AC
5 Die,e3tri3 Strengt- 5.9 kV or $ !in'te
1 C'rrent Ratings $000A
9 Rated Ser"i3e
S-ort 3ir3'it
)reaking
3a6a3it*#I3s%
90kA
8 Rated S-ort ti!e
7it-stand
3a6a3it*#I37%
90 kA or $ se3
A Rated ',ti!ate
s-ort )reaking
3a6a3it*#I3'%
90kA
@ Rated 6eak !aking
Ca6a3it*#I3!%
$00kA
/ S6ring 3-arging
Ti!e
$0se3
$0 Ar3ing Ti!e
$0 ! se3
$$ S6ring C-arging
!otor
Se, 6o7ered
$4 Prote3tion 5 OIC and $ EI; re,ease(4 OIC and
$ EI; re,a*( ,o7 set EI; 6rote3tion
'sing CT at ne'tra, eart-ing
3ond'3tor. RE; 6rote3tion re,a*
LUDHIANA 93
7it- 6ri!ar* tri6.
$5 Prote3tion de"i3e Mi3ro6ro3essor )ased
Re,ease 7it- 7ide se,e3tion o
3'rrent ? ti!e setting or -ig-est
degree o s*ste! dis3ri!ination
?3o2ordination 7it- do7n strea!
MCC>Gs
$1 ;eat'res o
6rote3tion de"i3es
C'rrent setting 3an )e 3-anged to
@0F o )ase 3'rrent )* )ase +
3'rrent se,e3tor s7it3- 7it-o't
s7it3-ing o AC> and 7it-o't
3-anging o AC> and 7it-o't
3-anging CT ta66ings. >'i,t in
o6eration 3-e3k 'n3tion e,i!inates
need or se6arate test instr'!ents .
Eart- ;a',t e,e!ent in3or6orated in
tri6 de"i3e 7it- ad&'sta),e t-res-o,d
< $4 r#ON ? O;;% ti!e setting
e,i!inates need or se6arate eart-
a',t re,a*. LEDI;LAG indi3ation to
s-o7 dis3ri!ination )et7een
o"er,oad s-ort 3ir3'it and EI;
tri66ing . It s-a,, not )e 6ossi),e to
7it-dra7 t-e )reaker 7-en s6ring is
3-arged. It s-a,, not )e 6ossi),e to
insert t-e )reaker ra3king -and,e
7-en 3')i3,e door is o6en.
$9 A33essories or
Dra7 o't t*6e
AC>Gs
Saet* s-'tter 6osition s7it3-.
S7it3- 3ir3'iting 3onta3t( Ma,2
insertion 6re"ention de"i3e. Test
LUDHIANA 94
&'!6er (6ad,o3king ( s-'nt tri6
3oi, (3,osing 3oi,( 3,ose o6en 3*3,e
3o'nter. It s-a,, -a"e deeat
inter,o3k a3i,it*.
$8 S-'nt tri6 50V DC
$A Inter,o3king Ke* Lo3kICast,e Lo3k I 6ad Lo3k I
Me3-ani3a, Inter,o3k I Door
Inter,o3k.
$@ Standards ? Tests ASTA I IEC /1A24 Categor* T>U.IS
$5/1A24 s'ita),e or iso,ation as
deined )* re,e"ant 3,a'ses in IEC
/1A24I IS $5/1A24(Indian Register
o S-i66ing Certiied or S-o3k
resistant '6to A0g "erti3a, 50g
-oriEonta, or 8 !se3 ( "i)ration
resistant or $0299 HE 0.A9
dis6,a3e!ent.
Rated s-ort ti!e 7it-stand #I37% or 0.9 se3 s-o',d )e eD'a, to t-e
rated ser"i3e )reaking 3a6a3it* #I3s% and eD'a, to t-e ',ti!ate
)reaking 3a6a3it*#I3'%.
Genera, s6e3ii3ations or t-e !o',ded 3ase 3ir3'it )reaker.
T-e !o',ded 3ase 3ir3'it )reaker 'sed in t-e s')station is 1 in
n'!)er . T-ere are 5 MCC>Gs o t-e rating o 490 a!6s and $ o t-e
rating o $00 a!6s.
LUDHIANA 95
LUDHIANA
INPLANT TRAINING
AT
CROMPTON GREAVES LIMITED.
TRANSFORMER DIVISION (T1)
KANJUR (EAST), MUMBAI 400 042.
SUBMITTED BY
LUDHIANA 96
KUNAL SHARMA
DEPARTMENT ELECTRICAL ENGINEERING
SEVENTH SEMESTER, ROLL NO. !!011!4.
YEAR 2002"200#
2< ACKNO=LEDGEMENT <2
=it- d'e res6e3t and gratit'de( I take t-is o66ort'nit* to e:6ress
!* sin3ere t-anks to t-e !anage!ent o MIs. Cro!6ton Grea"es Ltd.
or gi"ing !e t-is o66ort'nit* and e:3e,,ent 3-an3e to 'ndergo !* VII
t-
Se!ester In2P,ant Training at t-e Transor!er Di"ision #T$% at Kan&'r(
Marg M'!)ai.
I e:tend !* gratit'de to Mr V.S-i"k'!ar #Sr. E:e3'ti"e o
Ind'stria, design%( Mr. San&a* Nair #Design E:e3'ti"e %( Mrs
S-')-angi K',karni #Design E:e3'ti"e %( and or t-eir 3onstant
en3o'rage!ent and 6ro6er g'idan3e d'ring !* In2P,ant Training
6eriod. Des6ite a "er* tig-t s3-ed',e and a rigoro's 7ork )'rden( t-e*
-a"e a,7a*s o'nd ti!e to g'ide !e( -a"e not on,* !ade t-e training
ri3-er )'t -a"e a,so in3reased !* kno7,edge in t-e s')&e3t !anio,d.
LUDHIANA 97
I a! e:tre!e,* t-ank', to ot-er engineers( sta !e!)ers and
7orkers 7-o -a"e s6ared t-eir 6re3io's ti!e or 6ro"iding !e "a,'a),e
inor!ation gi"en in t-e re6ort and -a"e !ade t-is training a s'33ess.
I a,so a3kno7,edge !* gratit'de to Mrs. Ann Lo)o( Personne,
E:e3'ti"e or e:tending t-e 3o2o6eration to !e.
#K'na, S-ar!a%
LUDHIANA 98
CONTENTS
CHAPTER2$ INTRODUCTION TO THE COMPANP
CHAPTER24 INTRODUCTION TO TRANS;ORMER DIVISION.
CHAPTER25 TRANS;ORMERS
CHAPTER21 DRP TPPE TRANS;ORMER
CHAPTER29 PRE;A>RICATED SU>STATIONS
CHAPTER28 850 KVA ( $$K"I155V P.S.S
CHAPTER2A TRANS;ORMER IN P.S.S
CHAPTER2@ CONCLUSION.
LUDHIANA 99
CHAPTER-1
INTRODUCTION TO THE COMPANY
LUDHIANA 100
LUDHIANA 101
CHAPTER-2
INTRODUCTION TO TRANSFORMER DIVISION
CHAPTER-3
LUDHIANA 102
TRANSFORMERS
LUDHIANA 103
CHAPTER-4
DRY TYPE TRANSFORMERS
LUDHIANA 104
CHAPTER-5
PREFABRICATED SUBSTATIONS

LUDHIANA 105
CHAPTER-6
630KVA,11KV/433V PREFABRICATED SUBSTATION
LUDHIANA 106
CHAPTER-
TRANSFORMER IN PACKA!ED SUBSTATION
LUDHIANA 107
CHAPTER-"
CONC#USION
LUDHIANA 108
LUDHIANA 109

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PROJECT REPORT ON PREFABRICATED SUBSTATIONS

GURU NANAK DEV ENGINEERING COLLEGE

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