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Report On Transformer Manufacturing
Report On Transformer Manufacturing
ON
MANUFACTURING OF POWER AND
DISTRIBUTION TRANSFORMER
SUBMITTED BY
RAJ MOYAL
Roll no.-084022
3rd year B.Sc.Engg(Electrical)
Faculty of Engineering
Dayalbagh Educational Institute
ACKNOWLEDGEMENT
I underwent training program of thirty days from 1 st of June 2010 to 5th of July 2010 in
Marsons Electrical Industries which is the leading transformer company in India.For
this training program I would like to thank Mr.Umasankar Jaiswal,Q.C.Manager of the
Marsons Electrical Industries who arranged the training for me .And also I would like
to thank the whole staffs of the company for their guidance and kind supervision and
who cooperate with us.
(RAJ MOYAL)
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LAYOUT
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INTRODUCTION
The Company
Established in 1973, Marsons is a leading player in the business of manufacturing to
Transformers based in India.It is situated at national highway no.2,artoni ,agra (uttar
Pradesh). It is an ISO 9001 certified company having an extensive product range of
Power & Distribution Transformers from 10 KVA to 20,000 KVA .Almost 400 workers
are employed in the industry.Marsons has a sale turnover of about 500 million.it meet
the requirement of several state electricity board and it has its client in the foreign
countries as U.K,Nigeria,Africa,yemen and Syria.It has well established in the market
of Indian power sector. It products are designed to meet the requirement of the
global market.
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quality of the Coils of the transformer, winding wires and strips are also
manufactured in house.Fabrication section ensure the robustness, quality and fine
finish of the tank and radiators of the transformer.Marsons produces several types of
transformer as corrugated wall panel,self protected type,ground mounted,
hermetically sealed type with gas cushion. e complete test
The manufacturing process of Transformer cover the following
Fabrication of tanks
Core Assembly
Coil Winding
Core-Coil Assembly
Tank-up
Transformer Tank Painting & Finishing
.
INTRODUCTION ABOUT TRANSFORMER
Transformer is an ac machine that transfers electrical energy from one electrical
circuit to another without changing frequency by the principle of electro magnetic
induction.Since it’s basic construction requires no moving parts so it is often called
the static transformer and it is very rugged machine requiring the minimum amount
of repair and maintenance.Owing to the lack of rotating parts there are no friction or
winding losses.Further ,the other losses are very low so that the efficiency should be
high.The efficiency varies from 97% to 99%.
OPERATING PRINCIPLE
The action of a transformer is based on the principle that energy may be efficiently
transferred by induction from one set of coils to another by means of varying
magnetic flux , provided that both the sets of coils are on a common magnetic
circuit.The emfs are induced by the variation in the magnitude of flux with time.It is
based on Faradays law of electromagnetic induction.
POWER TRANSFORMER
The term is used to include all transformers of large sizes(250kva and above) used
in generating stations and substations for transforming the voltage at each end of a
power transmission line.They may be single or three phase and voltage rating of
220/11kv or in high voltage range.They are put in operation during load hours and
disconnected during light load hours or operated on full load.So power transformer
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are desined to have maximum efficiency at full load(i.e.with iron loss to full load
copper loss ratio of 1:1).
DISTRIBUTION TRANSFORMER
Transformer of rating upto 200kva,used to step down the distribution voltage to a
standard service voltage are known as distribution transformer.They are kept in
operation all the 24 hours a day.In such transformer iron loss occur for all the time
where copper loss occur only when they are loaded.Therefore,distribution
transformers should be designed with iron loss smaller in comparision to full load
copper loss(say with iron loss to full load copper loss ratio 1:3)
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TECHNICAL PARAMETER OF TRANSFORMER
Transformer shall be oil immerged ,hermetically sealed with corrugated
tank.The technical parameters of the transformer shall be as below..
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FABRICATION SHOP
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Transformer tanks are fabricated in this department.Fabrication include cutting of
sheets,straightening,bending,welding of sheets and parts of tank.
It has three sub shop
1.Sheet cutting
2.Machine shop
3.Welding shop
Machine shop has following machines
CNC Hypertherm automation machine
it is used for cutting metal based on design automatically. Gas used methane
hydrogen operating plasma system completes an electric circuit between the
torch and the workpiece.Specification microprocessor control system
Model FINCUT DP
Rail length 10000mm
Rail garage 3500mm
Input voltage 220v ac
Total power 5000VA
IS NO.10138
Punch press
This is used to cut different shapes on sheet by using different dies .The dies are
made of steel.
Rolling machine
This is used to straightened or to roll the sheets as per requirement.Roll can be at
any extent .After cutting of sheets ,they are introduced into it for straightning.
Lathe machine
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It is multipurpous machine and is used for giving shape to the fittings of transformer
tank like lifting lugs and jacking lugs.
The
entire assembly is done on a frame commonly known as core channel. These frames
being used as a clamping support of the core assembly. Three-phase transformer
usually employ three-leg core..The sectional areas of the yoke and side leg are 50%
of that of the main leg; thus, the core height can be reduced to a large extent
compared with the two leg core.For core material, high-grade, grain oriented silicon
steel strip is used connected by a core leg tie plate;fore and hind clamps by
connecting bars. As a result, the core is so constructed that the actual silicon strip is
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held in a sturdy frame consisting of clamps and tie plates,which resists both
mechanical force during hoisting the core-and-coil assembly and short circuits,
keeping the silicon steel strip protected from such force.In large-capacity
transformers,which are likely to invite increased leakage flux, nonmagnetic steel is
used or slits are provided in steel members to reduce the width for preventing stray
loss from increasing on metal parts used to clamp the core and for preventing local
overheat.The core interior is provided with many cooling oil ducts parallel to the
lamination to which a part of the oil flow forced by an oil pump is introduced to
achieve forced cooling.When erecting a core after assembling, a special device
shown is used so that no strain due to bending or slip is produced on the silicon steel
plate.The steel strip surface is subjected to inorganic insulation treatment.. Yokes are
jointed at an angle of 45 degree to utilize the magnetic flux directional characteristic
of steel strip.A computer-controlled automatic machine cuts grain-oriented silicon
steel strip with high accuracy and free of burrs, so that magnetic characteristics of
the grain-oriented silicon steel remains unimpaired.Silicon steel strips are stacked in
a circle-section. Each core leg is fitted with tie plates on its front and rear side, with
resin-impregnated cotton tape wound around the outer circumference. Sturdy
clamps applied to front and rear side of the upper and lower yokes are bound
together with tape.And then, the resin undergoes heating for hardening to tighten the
band so that the core is evenly clamped .Also, upper and lower clamps are evenly
tight.
COIL WINDINGS
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Windings form another important part of transformers.In a transformer,the high and
low voltage windings are so designed that the axial short circuit force is reduced to
minimum.Transformer winding are made of copper or aluminium strip
conductor.Heavy current capacity needs conductors of large cross section.To reduce
eddy current losses in the conductors ,several small wires or parallel straps are
preferred to one large strap.This give rise to unequal reactance of the component of
the conductors which can be eliminated by transposition of conductors.Instead of
placing primary on one limb and secondary on the other limb it is usual practice to
wind one half of each winding on each limb.This ensures tight coupling between the
two windings.consequently leakage flux is reduced.The positioning of the hv and lv
winding with respect to core is also very important from the point of view of insulation
requirement.If hv winding were placed next to the core ,it would be necessary to
insulate it from the core and lv winding and two layer of hv insulation would be
required.By placing hv winding outside and around the lv winding only one layer of
hv insulation would be required. The one which is connected to a voltage source and
creates the flux is called as a primary winding. The second winding where the
voltage is induced by induction is
called a secondary.It may be more
appropriate to designate the windings
as High Voltage (HV) and Low
Voltage (LV) windings. The winding
with more number of turns will be a
HV winding.
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and ,therefore,they are widely employed both as lv and hv windings in large rating
transformers.
Interleaved disk winding
In this winding, electrically isolated turns are
brought in contact with each other as shown. Thus,
the winding is termed "interleaved disk winding."
Since conductors 1 - 4 and conductors 9 - 12
assume a shape similar to a wound capacitor, it is
known that these conductors have very large
capacitance.This is the most general type
applicable to windings of a wide range of voltage
and current. This type is applied to
windings ranging from 350kV to
1550kV.Rectangular wire is used where
current is relatively small, while transposed cable is applied to large current. When
voltage is relatively low, a transformer of 100MVA or more capacity handles a large
current exceeding 1000A. In this case, the advantage of transposed cable may be
fully utilized.Further, since the number of turns is reduced, even conventional
continuous disk construction is satisfactory in voltage distribution,thereby ensuring
adequate dielectric characteristics. Also,whenever necessary, potential distribution is
improved by inserting a shield between turns.
Cross over winding. These are made of circular conductors not exceeding 5 to 6
sq mm in cross section. These are used for HV windings of relatively small
transformers. These turns are wound in several layers.The length and thickness of
each block is made in line with cooling requirements. A number of such blocks can
be connected in series, leaving cooling ducts in between the blocks, as required by
total voltage requirement.
Helical winding
One very common cylindrical coil arrangement is the helical winding. For windings of
low voltage (20kV or below) and large current, a is helical coil is used which consists
of a large number of parallel conductors piled in the radial direction and wound.This
is made up of large cross section rectangular conductor wound on its flat side.The
coil progresses as a helix. This is commonly used for LV windings. The insulation
requirement also is not too high. Between layers no insulation (other than conductor
insulation) is needed as the voltage between layers is low. The complexity of this
type of winding rapidly increases as the current to be handled becomes more. The
conductor cross section becomes too large and difficult to handle. The eddy current
losses in the conductor rapidly increases. Hence two or more conductors have to be
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wound and connected in parallel. The parallel circuits bring in problems of current
sharing between the circuits. Transpositions of the parallel paths have to be adopted
to reduce unequal current distribution. The modern practice is to use continuously.
transposed and bunched conductors
Coil assembly
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1. High Voltage Coils: H.V. Coils are the components of finished transformers.
They are made on automatic layer setting winding machines. A solid cylindrical
former of predetermined diameter and length is being used as base over which it is
made.
Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as
basic raw material. The coils are made in number of layers. The starting and finishing
leads of each coil are terminated on either side of the coil. These leads are properly
sleeved and locked at number of points.
2. Low Voltage Coils:
L.V. Coils are also one of the components of transformer. The procedure of making
low voltage coil is generally same as described earlier. The shape of the basic raw-
material (Al or Cu) is rectangular. The Test: The "Turn Test"
is carried out on the H.V. Coils as per the specifications.
Transformer Tank
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Marson’s will have an in-house facility for manufacturing transformer tanks. All tanks
are made of high quality steel and can withstand vaccum as specified by the
international standards and the customer. All welds are tested, ensuring 100% leak
proof of seams and mechanical strength. All transformer tanks are given a smooth
finishing by using the "SHOT BLASTING" process.
Transformer tanks commonly used are of the following types;
1. Plain sheet steel tank.
2. Sheet steel tank with external cooling tubes.
3. Radiator tanks.
4. Tanks with corrugated wall panels
The tank is manufactured by forming and welding steel plate to be used as a
container for holding the core and coil assembly together with insulating oil.
Transformer tank offers the following features:Subjected to automatic beam welding
machine and other special facilities, the tank possesses high quality and
strength.Transformers to be transported by ship are structured in a semioval shape
on both ends of the tank and provided with reinforcement members rationally
arranged, resulting in increased strength and decreased weight.The tank bottom is
fitted with a skid base by welding and provided with pull lugs to facilitate rolling in the
longitudinal and transverse directions.Capable of withstanding a high vacuum of 0.1
torr or below, the tank can be filled with oil under a vacuum; to thoroughly remove
gases and moisture from the insulation.The tank is of completely enclosed,welded
construction.Oilproof nitrile rubber gaskets are used on those parts which must be
removed from the standpoint of assembly in the field or during maintenance; flanges
thereon are provided with machined grooves or gasket retainers to ensure proper
tightening of gaskets. Consequently, there is no possibility of oil leakage over an
extended period.
TANK UP
Assesories - spanner,hammer,plyier,knife,nose plyier,ring snapper,slide
ringe,crimping tools,blower,megger instrument,chisel,tape scale,micrometer The
core-coil assembly and tank supplied by the fabrication deptt. are taken into tank-up
stage. The procedure is:
The core-coil assembly is taken out of the oven and the "Megger
test" is carried out. Only if the megger value is as per the
specification, the assembly may be taken for tank-up. The tanks,
supplied by fabrication deptt. are brought to tank-up department
duly painted. Fittings like drain valves, HV& LV Bushings,
conservator, oil level indicator and explosion vent are fitted in the
tanks. The Core-coil assembly is then placed into the tank and
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properly locked up. Pure filtered transformer oil is filled in the tank to immerse the
assembly only. Connections of primary and secondary to the terminal bushings are
made. Operating handle for ratio switch is fitted, wherever required. .
TESTING OF TRANSFORMER
Marson’s carries away almost all type of routine test .Type test(impulse/voltage) is
being done at CPRI Bhopal National Test House,Gaziabad and Government
Engineering College,Jabalpur..Testing is done as per IS 2026.
Routine test to be carried out on all jobs.
Measures the insulation resistance of HV & LV windings with respect to earth (body)
and between LV & HV winding.Recommended Values are 2000Mohms for HV & 500
Mohms for LV and between Primary & Secondary.HV high voltage test : LV winding
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connected together and earthed. HV winding connected together and given 28 KV
( for 11KV transformer) for 1 minute.
INSULATION TESTER OR MEGGER IS USED.
This test checks the inter turn insulation.For a 11KV/433V transformer,866 Volts
are applied at the 433V winding with the help of a Generator for 1 minute. This
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induces 22KV on 11KV side. The frequency of the 866V supply is also increased
to 100HZ.
Equipment used : MOTOR GENERATOR SET
This test measures the voltage ratio as per the customer’s requirement.
V1/V2 = N1/N2
The voltage ratio is equal to the turns ratio in a transformer. Using this principle, the
turns ratio is measured with the help of a turns ratio meter. If it is correct , then the
voltage ratio is assumed to be correct. Equipment used : Turns Ratiometer
6.Measurement of NO LOAD LOSS & current.
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The iron losses and no load current are measured in this test. The 433V winding is
charged at 433V supply & the 11KV winding is left open .The power consumed by
the transformer at no load is the no load loss in the transformer.
Effect of actual frequency must be taken into account.
Equipment used : Wattmeters analyser or power.
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This test measures the power consumed by the transformer when the 433V winding
is short circuited and The rated current is passed through the 11KV winding.
Equipment used : Wattmeters or power analyser.
This test verifies the Dyn-11 vector group of a distribution transformer.Let the
transformer vector group is DYn11;
1.1U 1V 1W-which is primary -Delta Connection
2.2U 2V 2W 2N- Which is secondary-Star connection
3.By connecting terminals 1U& 2U
4.Then three phase Supply is given to 1U-1V-1W
5.By measuring the terminal given below
We get
a. 1U-1V
b. 1V-1w
c. 1W-1U
d .1W-2W
e. 1V-2W
f. 1V-2V
g. 1W-2V
h. 1U-2N
i. 1V-2N
THE BELOW GIVEN CONDITION IS SATISFIED THEN DYn11 IS
CONFIRMED
1.1V-2W=1V-2V
2.1W-2V>1W-2W
3.1U-1V=1V-2N+1U-2N
ACCESSORIES
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Conservator is normally provided on all ratings of transformers which provides the
space for the expansion / contraction of oil on account of the variation of oil
temperature during service. It prevents the oil in the tank from coming in direct
contact with the atmosphere and protects it from deterioration.Conservator is
provided with silicagel breather, oil level gauge, oil filling hole with blanking plate and
drain plug for draining/ sampling of oil contaminated by moisture and sludge.
MARSHALLING BOX
The transformer is provided with certain fittings directly mounted on the transformer
at various locations. These fittings are having electrical contacts or terminals which
are required to be connected to the protection schemes to give alarm/annunciation
under abnormal conditions and if further required to disconnect the transformer from
mains. In order to facilitate connections of all such devices to the protective scheme,
the cables from all such contacts are wired upto a weather proof terminal box. This
box called marshalling box, is also used for housing Oil Temperature Indicator (OTI)
and winding Temperature Indicator (WTI)The Marshalling box is made of sheet metal
and is provided with a glass window for observing OTI& WTI .Is has a hinged door
with locking facility to prevent unauthorised access. The capillaries from OTI& WTI
come out from the bottom of the Marshalling box through suitably recessed gland
plate thus preventing ingress of dust.
Liquid Temperature Indicator
Liquid temperature indicator is used to measure oil temperature as a standard
practice. The dial temperature detector is used to measure maximum oil
temperature.The indicating part, provided with an alarm contact and a maximum
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temperature pointer, is of airtight construction with moisture absorbent contained
therein; thus, there is no possibility of the glass interior collecting moisture whereby it
would be difficult to observe the indicator.
0.7kg/cm2 the pressure relief device starts automatically to discharge the oil. When
the pressure in the tank has dropped beyond the limit through discharging, the
device is automatically reset to prevent more oil than required from being
discharged.
Protective Relays
The following protective devices are used so that, upon a fault
development inside a transformer, an alarm is set off or the
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transformer is disconnected from the circuit. In the event of a fault, oil or insulations
decomposes by heat, producing gas or developing an impulse oil flow.To detect
these phenomena, a Buchholtz relay is installed
Buchholtz Relay
The Buchholtz relay is installed at the middle of the connection pipe
between the transformer tank and the conservator. There are a 1 st stage contact and
a 2nd stage contact as shown.
The 1st stage contact is used to detect minor faults. When gas produced in the tank
due to a minor fault surfaces to accumulate in the relay chamber within a certain
amount, the float lowers and closes the contact, thereby actuating the alarm
device.The 2nd stage contact is used to detect major faults. In the event of a major
fault, abrupt gas production causes pressure in the tank to flow oil into the
conservator. In this case,the float is lowered to close the contact, thereby causing the
circuit breaker to trip or actuating the alarm device.
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The transformer is fitted with an off-circuit tap changing switch to obtain required tap
voltage. It can be hand operated by a switch handle mounted on the tank. Locking
device is fitted to the handle to padlock it on any tap position and also to prevent any
unauthorized operation of switch. The switch mechanism is such that it can be
locked only when it is bridging two contacts on any particulars tapping position and
cannot be locked in any intermediate position.It is important that the transformer
should be isolated from the live lines, before moving the switch. Operating the switch
when transformer is energized, will damage the switch contacts due to severe arcing
between the contacts, and may damage windings also.
Temperature gauges
A Temperature Gauge is a common safety device installed on transformers,
regulators and other electrical equipment when filled with liquid insulating fluids for
dielectric insulation and cooling.. A temperature gauge is installed to measure the
changes in the temperature of the liquid insulating fluids.Temperature gauges
provide a positive system to measure and indicate the insulating fluids temperature
in transformers, regulators and other electrical equipment.
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number of sections per radiator and the number of radiators per transformer will
depend upon the losses and permissible temperature rise.Distribution Transformers
are normally provided with Radiators welded to tank. Each radiator consists of
number of "Sections made from pressed sheets forming channels for oil flow.
These "Sections" are welded to Header Pipes at Top & Bottom.
Circuit breaker
Circuit Breakers provide short circuit and thermal protection for both pad mounted
and overhead distribution transformers. These are applied immersed in the
transformer oil on the low voltage side to protect the transformer against secondary
faults and excessive overloads.
BUSHING
a) Bare bushing :
COOLING OF TRANSFORMER
.
Cooling of the transformer is the most important for it’s durability.As the rating
increases better cooling techniques are needed. Simple air cooling of the
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transformers is adopted in dry type transformers. The limit for this is reached by the
time the rating is a few kVA.This method of cooling is termed as AN(Air Natural). Air
Blast(AB) method improves on the above by directing the blast of air at the core and
windings. ON (Oil Natural) This method permits the increase in the surface available
for the cooling further by the use of ducts, radiators etc.OB(Oil Blast) method is an
improvement over the ON-type .and it directs a blast of air on the cooling surface. In
the above two cases the flow of oil is by natural convective forces. OFN (Oil Forced
Natural)in this a forced blast of oil is employed.When there is blast of air,the cooling
method become OFB(Oil Forced Blast). A forced circulation of oil through a radiator
is done with a blast of air over the radiator surface. Next comes OFW which is
similar to OFB except that instead of blast of air a forced circulation of cool water in
the radiator is used in this.
Self-cooling type
(ONAN) 30,000kVA or below Panel-type radiators
Forced-air-cooled
type (ONAF) 30,000kVA~150.000kVA Panel-type radiators and cooling fans
Forced-oil, forced-aircooled
type (OFAF) 150,000kVA or more Unit cooler or panel-type radiator, and
Installation of cooling fans and pumps
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PAINTING AND FITTINGS
: The entire procedure of painting is done under two stages:
1. Cleaning of tanks
The cleaning of tank is done normally by chipping/grinding. The outside surface of
the tank is short blasted to achieve a very fine and smooth finish.
2. Painting of tanks
After cleaning the tanks, a coat of hot oil resistence paint is applied on the internal
surface of the tank.
The outside surface is painted with a coat of Red Oxide primer and
subsequently with one coat of enamel paint as per customer's
requirement.
Fittings and accessories as per customer's specification and drawing are checked.
Air Pressure test is subjected to avoid any leakage and seepage on all
transformer.Transformers are filled with oil upto the minimum level marking,
wherever necessary.
Summary
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At last I would like to say that this training was a success for me,as I learned a lot
about the manufacturing ,design and other aspects of transformer which could not
have been learned otherwise.As I have already mentioned that Marsons Electrical
Industries is the leading transformer company of India.Company designed the
transformer by well defined quality policy accourding to the ISO-9001:1994
standard.The company acquired quality system certificate from Det Norske
Veritas,vide Certificate No. RIN 350-AQ-1746 dated 14.06.2001.
Company not only supply their products in India but also in foreign countries
like U.K,Nigeria,Seria,etc.There products are of very good quality and process is
carried out in required environment.The staffs are very experienced and guide with
interest.
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