Welcome to My

Presentation

Prodip Kumar Das

ID#11105136
Program : BSEEE
 Study on
Manufacturing of 11/.415kv Distribution
Transformer
at Navana Electronics Limited

2 1/2/2015
 Contents…..
 Objective

 Company Profile

 Basic Theories

 Working Principle of Transformer

 Distribution Transformer

 Oil immersed distribution Transformer

 Manufacturing of 3-Phase Distribution Transformer

 Recommendations

3 1/2/2015
 Objectives…..

 To apply theoretical knowledge in the practical field

 To observe the manufacturing process of distribution transformer, testing

 Collecting knowledge regarding distribution transformer

 Developing skills and techniques relevant to our careers

4 1/2/2015
 Company Profile….
 Name: Navana Electronics Limited

 Factory location: Bashtola, Shahazadpur, Gulshan -2,

Dhaka-1212

 Ownership: Navana Group

5 1/2/2015
 Contd.
Products:

PFI LT Switchgear HT Switchgear

6 1/2/2015
 Contd.
Products:

Transformer

In NEL, the producing three phase transformers are oil

immersed distribution transformer and their cooling system
is ONAN type.
7 1/2/2015
 Basic Theories….

1. Transformer is an electrical device that

transfer electric power from one circuit to
another
2. It does so without a change of frequency
3. It accomplishes this by electromagnetic
induction
4. Where the two electric circuits are in
mutual inductive influence of each other

8 1/2/2015
 Working Principle of Transformer….

9 1/2/2015
 Distribution Transformer…..
• Used for distribution of electrical energy

 Generally, operates at low voltage as less than 33KV in industrial purpose

and 440v-220v in domestic purpose

 Three phase distribution transformers ,widely used in 11kv distribution

line to step down the voltage level.

10 1/2/2015
 Oil immersed distribution Transformer….

11 1/2/2015
 Manufacturing of 3-Phase Distribution
Transformer

12 1/2/2015
13 1/2/2015
  Active Part :
The ferromagnetic core
and windings

14 1/2/2015
 Transformer manufacturing procedures….

15 1/2/2015
 Core material…. …
 The mostly used core material
is CRGO-Cold Rolled Grain
Oriented steel sheets of 3% of
Silicon

 Thickness of the CRGO sheets

usually 0.27 mm

 Oxide coating is provided for

CRGO laminations to reduce
eddy current losses

16 1/2/2015
 Core Cutting….

Straight type core cutting

17 1/2/2015
 Core Jointing on Channel….

 This is the simplest form of joints

 The flux leaves and enters at the joint in

perpendicular

18 1/2/2015
  Placing laminated sheets by hand or
hammer manually

 No air gap between the joints of two

consecutive sheets

 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

19 1/2/2015
Covering copper wire with Insulating Tape…..

 The mostly used material for

winding wires or strips is
copper .

 The copper wires or strips are

wrapped by insulating tape or
DPC paper.

20 1/2/2015
 Low Voltage Windings…..

Vertical machine is used to

prepare the LV winding

The helical and double layers

 Number of turns varies on

KVA rating
21 1/2/2015
 Low Voltage Windings…..
Starting End

Finishing End

Gape between two layers

 Greater simplicity in fitting

cooling ducts

 More even heat distribution

through the windings

22 1/2/2015
 High Voltage Windings….
 Horizontal machine is used to prepare the
HV winding

 HV windings are of layered construction

 The conductors are made of more round

wires, either with an insulating paper

 The insulation between the layers

consists of DPC paper

23 1/2/2015
 High Voltage Windings…..

24 1/2/2015
 Contd.
Insulation between two layers :

Insulation between
two layers of DPC
paper

25 1/2/2015
 Core-Coil Assembly…..

Opening the upper yoke

26 1/2/2015
 Contd.

Cotton tape

Press board

Insulating between core and LV winding

27 1/2/2015
 Contd.
Placement of LV Winding:

 The LV windings in the core

limb .

 They are fitted tightly in all

three limb using pressed board.

28 1/2/2015
 Contd.
Isolating HV from LV winding:

Press Board Cutting DPC Paper

29 1/2/2015
Contd.

Before inserting the HV winding

30 1/2/2015
 Contd.
Placement of HV Winding:

 This coil is placed on LV winding

as second layer of core

 First LV coil then HV coil

 The gap between the LV and HV

coil is filled with runner of pressed

board

31 1/2/2015
 Contd.
Inserting the Upper Yoke:

The active part before connection

32 1/2/2015
 Connections…..

HV Side ( Delta Connection) LV Side (Star Connection)

33 1/2/2015
 Contd.

34 1/2/2015
 Vector grouping.....
The vector grouping in NEL is Dyn 11:

 Delta connected HV winding

 Star connected LV winding

 Neutral brought out

 LV is leading HV with 30° (11

o’clock)

35 1/2/2015
 Tap Changer…..
 Tapping is terminated just
bellow oil level
Tap Changer
 External handle

External Handle
 Taping is done on HV winding

 Used to regulate the output

voltage to required levels

36 1/2/2015
pe

How Tapping done:

Taping Wires
Connected to HV
Changer coils

37 1/2/2015
Moisture Control…..
 The whole active part of the transformer

in the heat chamber

 Keeping it there for 72 to 96 houres with

a continuous heating temperature of

100° - 141° C to clean the moistures in it

 Bringing it out after getting proper

insulation

38 1/2/2015
 The Tank…..

39 1/2/2015
 Functions of Transformer Tank...

 A container for the cooling liquid

 Providing shielding against

electromagnetic field leakage

40 1/2/2015
 Radiator….

 Made steel like tank

 Attached with the tank

 Radiate the heat from

insulating oil and makes the
oil cool

41 1/2/2015
 Inserting The Active Part Into The Tank…..

 Whole active part is covered by

press board

 Crane is used to lift the active part

 By handling a chain the active part

is put slowly in the tank

42 1/2/2015
 Bushings….
Conductor

 Counteracting the electrical field

Insulator strength

 Insulating the incoming or outgoing

conductor into or out of the transformer

tank

43 1/2/2015
Conservator….
 Providing adequate space for
expansion of oil inside the tank

 It also acts as a reservoir for the

insulating oil.

 The oil level indicator indicates the

oil level

 Oil level should not fall below

minimum limit

44 1/2/2015
 Filling Oil…..

45 1/2/2015
 Function of Transformer Oil….

 Providing dielectric strength

to the insulation system

 Providing efficient cooling

 Protecting of the transformer

core and coil from chemical
attack

46 1/2/2015
46
 QC Tests….

Testing of Distribution Transformer:

 Insulation test
 Ratio test

 Open circuit test

 Short circuit test

47 1/2/2015
48 1/2/2015
Rating Plate

49 1/2/2015
 Ready to Delivery

50 1/2/2015
 Recommendation…..

 NEL should cut the core sheets as angular core cutting and arrange

the core sheets by mitered joint system to reduce core loss.

 The transformer manufactured by NEL should always use Buchholz

Relay that protects the transformer all the time and increase its life
time.

51 1/2/2015
 Contd.
Elaboration of My Recommendations:

 In Mitered core joints the flux

goes by an angle 450 .
 That is very smooth path for the
flux
 Cross grain loss is minimum and
core loss will be reduced

 If any fault occurs in

transformer buchholz rely
gives alarm and can protect the
transformer

52 1/2/2015
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