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CG Power and Industrial Solutions

Limited

Industrial Training report on

Manufacturing of loco transformer

Under the guidance of: Submitted by:

Piyush Ingle

Mr. Mayank Maheshwari BE – 3rd year

Branch – EX
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Index
Declaration
Acknowledgement
1. About CG
2. Introduction
3. Principle of Working
4. Different Parts and Components of Transformer
5. Process Flow chart Loco Transformer Manufacturing
6. Quality Check
7. Core Building
8. Winding
9. Core coil assembly
10. Autoclave
11. Insulation
12. Cooling Arrangement
13. Transformer Tank
14. Some Important Components
15. Test
16. Factor affecting life of Transformer
17. Finishing
18. Replacement of Asbestos.
19. Name plate of Loco Transformer
20. Conclusion
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Acknowledgement

The internship opportunity I had with CG Power and Industrial Solutions

was a great chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet
so many wonderful people and professionals who led me though this
internship period.

Bearing in mind previous I am using this opportunity to express my deepest

gratitude and special thanks to Crompton Greaves who in spite of being
extraordinarily busy with its duties, took time out to hear, guide and keep
me on the correct path and allowing me to carry out my project at their
esteemed organization and extending during the training.

Piyush Ingle
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DECLARATION

I hereby declare that the project work entitled “Manufacturing of Loco

Transformer” is an authentic record of my own work carried out at CG
Power and Industrial Solution Limited, Mandideep as requirement of 15
days training after 4th semester for the degree of B.E. (Electrical and
Electronics Engineering), Lakshmi Narain College of Technology, Bhopal
under the guidance of Mr. Mayank Maheshwari, CG Power and Industrial
Solutions Limited, Mandideep.

Date: Name- Piyush Ingle

Enrollment No.-0103EX161062

Certified that the above statement made by the student is correct to the
best of my knowledge and belief.

Mr. Mayank Maheshwari

CG Power and Industrial Solutions Limited

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1. About CG
1.1 History

Col. R. E. B. Crompton founded R.E.B. Crompton & Company in 1878. The

company was merged with F.A. Parkinson in 1927 to form Crompton Parkinson
Ltd. Greaves Cotton and Company, established by James Greaves in 1859, was
appointed as their concessionaire in India.[citation needed]

In 1937, Crompton Parkinson established Crompton Parkinson Works Ltd. in

Bombay as a wholly owned Indian subsidiary. In collaboration with Greaves
Cotton, it also established a sales organization, Greaves Cotton & Crompton
Parkinson Ltd. In 1947, just before India's independence, Lala Karam Chand
Thapar, an Indian industrialist, bought Greaves Cotton when the company was
put up for sale. With this acquisition, Karam Chand Thapar gained control of
several associated companies such as Crompton Parkison Works, Greaves Cotton
and Crompton Parkinson Company.

1.2 CG Offering

1.2.1 Power System

Power System includes the business area related to transformers, Switch Gears,
Circuit Breakers, Vacuum interrupters, network protection and gear control, as
well as design, execution and servicing of turnkey T&D as well as substation
projects. This is the largest business which is now well entrenched throughout the
world.

1.2.2 Industrial Section

CG industrial section is engaged in business of power conversion equipment a

wider spectrum of high and low voltage rotating machines, stampings, as well as
railway transportation and signaling products. Industrial System is largely India
focused with a strong market presence and market leadership position in many
segments. It also caters to foreign markets through its facilities in Hungary and
Exports.
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1.2.3 Transformer Section

CG is among the top 10 transformer manufacturers in the world., and one of the
very few companies worldwide that designs and manufactures a wide range of
power and distribution transformers and reactors.

The range of power Transformers offered is from 25 KVA to 600 MVA and 11KV to
765 KV class, and reactors from 10 MVAr to 125 MVAr, and 33 KV to 765 KV class.
These products are conforming to IEC, ANSI, IS, BS and other international
standards.
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2. INTRODUCTION
The transformer is a static device, which transform power from one AC
circuit to another AC circuit at same frequency but having different
characteristics. These circuits are conductively disjointed but magnetically
coupled by a common time varying magnetic field. It can raise or lower the
voltage with a corresponding decrease or increase in current.

In all the electric locomotives, limiting the value of

current during starting, speed control is achieved by supply of variable
voltage to the traction motors. This variation of applied voltage can be
carried out easily by the use of transformer along with tap changer provided
in the locomotive.

The windings which form the electrical circuit must fulfill certain basic
requirements, particularly the di-electric, thermal and mechanical stresses
imposed on it during testing as well as in service and cater for over loads
under adverse conditions.
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3. PRINCIPLE OF WORKING

In general principle of working of a transformer can be expressed on the

basis of law of electromagnetic induction as following:

a. When a conductor cuts the magnetic flux or magnetic flux cut the
conductor, an emf is induced in the conductor.

b. The magnitude of this emf is proportional to the rate of change of flux.

E = -dφ/dt

Where, E = emf

φ = flux

Kinds of emfs

The emf may be induced by two ways

i. Dynamically induced emf

ii. Statically induced emf.

a. Mutually induced emf

b. Self induced emf

An emf induced in a coil due to variation of flux in another coil placed near
to first is called mutually induced emf. The emf induced in a coil due to
change of its own flux linked with it is called self-induced emf. (In case of
autotransformer) In its simplest form, a transformer consists of two
conducting coils. The primary is the winding which receives electric power,
and the secondary is one which delivers the electric power. These coils are
wound on a laminated core of magnetic material.

The physical basis of a transformer is mutual induction between two circuits

linked by a common magnetic flux through a path of low reluctance . The
two coils possesses high mutual inductance. If one coil is connected to a
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source of alternating voltage, an alternating flux is set up in the laminated

core, most of which is linked up with the other coil in which it produces
mutually induced emf

i.e. E = M di/dt

If the second circuit is closed, a current flows in it and so electric energy is

transferred (entirely magnetically) from first coil (primary winding) to the
second coil (secondary winding).

4. DIFFERENT PARTS & COMPONENTS OF

TRANSFORMER
Transformer consists of the following parts and components.

1. Core and winding

2. Transformer tank

3. Protection system fittings

4. LV bushings

5. HV bushings

6. Main bushing

7. Conservator

8. Breather

9. Radiator

10. Oil circulating pump

11. Oil level indicator

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5. Process Flow Chart of Loco Transformer

Manufacturing

Start Finish

Winding Core Building

 Main Winding  Main Core

 GOD Winding  GOD Core
 SOD Winding  SOD Core Packing
Dispatch

Pressure
Test
Autoclave
Process

of Main
Winding Expansion
Core Coil Tank Filling
Connections and Oil Top Up
Assembly

Ratio Drying Tanking Out and Vacuum

Test Process For Oil Filling
Active
Assembly Pair
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6. Quality check
There are Two ways of Quality Check :-

1. Physically- In this way the components are checked physically i.e. there
should be no cracks, no impression or no damage to the components.

2. Dimensionally – In this components are checked by precise instruments

i.e. Vernier Calipers, Screw Gauge.

7. Core Building
The constructional features of a traction transformer are more or less same
as other power transformers. The locomotive transformer core is made
from cold rolled grain oriented steel of best grade and provides magnetic
circuit.

The magnetic circuit consists of a laminated core of interleaved

construction comprising of a Two-limbed construction. It is in the form of
thin sheet. The frame of core is made of permawood. The two limbs sits on
the base made of permawood connecting with the lower yolk.

Then coil compartment is assembled which is again made of permawood

and is fitted using resin glass FG pipe, screw and nut. This coil
compartment is fitted around the coil after the core coil assembly. After the
silicon steel is setup the silicon steel sheets are wrapped by two layers of
resin glass tape to hold the sheet. All core utilize step lap principle in the
corner joints to reduce losses, magnetizing current and sound level. The
laminations are stacked in steps resulting in a circular core shape which
gives the windings optimum radial support, especially during short circuit
conditions. Yokes are clamped by solid mild steel plates with yoke studs,
ensuring high rigidity for withstanding mechanical shocks.

The core is clamped using structural steel clamps which provide high
strength under both static and dynamic mechanical loads. The clamps are
very lightweight for their strength and provide a smooth surface facing the
winding ends, eliminating regions of high local electrical stress.
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8. Winding

In loco transformer the radial type of windings are done. This arrangement
provides the highest short circuit strength while providing good cooling of
conductor surfaces. The two limbs are provided with HV, LV, filter and
auxiliary windings. There are four traction windings on the LV side which
give power to the induction motor.

There is one filter winding which is responsible for reducing harmonics and
Bur winding which gives supply to the auxiliaries like fan, tube light and
charging ports.

Since the windings are of radial type between every disc there is a block
which avoids the direct contact of the two discs. Because direct contact of
two discs can burn the insulation and short circuit can take place. Between
the windings and the core spacers are placed. Some gap is left between
the two turns of the same disc so that the oil reaches between the coils.
SOD and GOD windings are also used.

Conductors are either paper or nomex covered copper wire or continuously

transposed cable. Conductor cross-section are chosen to be as large as
possible to minimize short – circuit stress , while ensuring that eddy losses
in the conductor are kept under control.

Windings types are selected by design engineer, depending upon the

specific application. Layer, Helical, Disc, Shielded and interleaved disc
types are all available to the designer, depending on the voltage and
current requirements of the design. Control of electrical stress is achieved
by placement of custom – designed stress rings on the end of high voltage
windings and anywhere else they are required.

Oil flow through the windings is directed in zigzag pattern to ensure cooling
of all conductor surfaces and to limit the hot spot temperature. Careful
attention is paid to ensure an even distribution of oil to all windings.
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9. Core coil assembly

The active part of the Transformer consists of the magnetic core with
windings and accessories. The windings are placed over the core limbs.
Before the connections are done brazing process is performed on the lead.
Brazing process is performed to remove the insulation and clean the leads
which are to be connected. After brazing carbon deposits on the leads. This
carbon is to be removed to ensure proper conductivity.

Now necessary connections are made as per the tapings. After this the
upper yolk is setup and coil compartment is clamped around the windings.
After the connections are made the insulation paper is wrapped on the
conductor.

Sufficient ducts are provided between the coils to ensure heat dissipation
through circulation of oil. Best quality insulation is provided at all joints and
gaps. The optimum design of Core-Coil Assembly is achieved by
considering the required technical particulars including cooling, size
compactness and tapping arrangement. All leads and conductors are rigidly
supported by special clamping arrangement.

Connection of lead ends coming out of winding to the bushing/Tap changer

is called lead connection. Normally the lead connections of low voltage
winding lead end is done on one side of the coils where as the high voltage
leads connections is done on the other side of the coils.
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10. Autoclave
Industrial autoclaves are pressure vessels used to process parts and
materials which require exposure to elevated pressure and temperature.
The manufacture of high-performance components from
advanced composites often requires autoclave processing

An autoclave applies both heat and pressure to the workload placed inside
of it. Typically, there are two classes of autoclave. Those pressurized
with steam process workloads which can withstand exposure to water,
while circulating heated gas provides greater flexibility and control of the
heating atmosphere.

Autoclave in transformer manufacturing is generally used 3 times –

1. First time the only the winding goes in the autoclave for about 36
hours. It is done to remove moisture from the winding assembly.
2. Second time the core coil assembly goes in the autoclave after the
brazing and connections are done for about 27 – 28 hours. It is again
done to remove the moisture. Because the till the time brazing and
connection are done the core coil assembly again gain moisture.
3. Third time the core coil assembly with the tank goes into the
autoclave for oil filling. It takes about 12 hours.

To remove moisture 100°c temperature and vacuum is created in the

autoclave. Electric Heating Systems are the most efficient plants for heating
up windings and with this, for transformer drying. The heating energy is
transferred solely to the conductor with high efficiency. Hence, different
transformer types require different plant concepts:
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11. Insulation
Since insulation is the most important factor for the traction transformer
winding, this requires much attention for the same. The insulation is pre-
compressed pressboard, which does not chip or get crushed under shock
loads. The entire coil assembly is carefully shrunk pre-determined clamping
pressure and controlled heat. A further safe guard against any minor
shrinkage in service, spring-loaded pressure pads are employed which
exerts a steady pressure on all the windings through sturdy steel plate.

As the space is at premium in electric locomotive, the pre-compressed

intersections insulation is match to close tolerance to avoid coil build-ups.
Insulation angle rings and angle barrier are place between HV and LV
winding. These are of method construction which brings compactness and
mechanical strength to the coil assembly. The insulation blocks are
carefully dimensioned and positioned between the windings so as to
ensure adequate strength to the coil and effective cooling. All the bolts and
nuts are properly secured to prevent loosening in service. All leads are
suitably clamped to prevent any possibility of a short circuit due to vibration.

12. Cooling Arrangement

To bring in desired compactness, the coolers are always of forced oil

forced air type (OFAF). The rate of oil flow and position of inlet and outlet of
the oil from the transformer are governed by consideration of optimum
cooling. The oil pump is of glandless type construction and is based near
the oil outlet. The oil from the coolers enters the transformer at the bottom
and then rises to the top near the outlet. To facilitate servicing and
replacement of major components in the cooling circuit the valve are
introduced at the appropriate places.

The complete cooling equipment is mounted on the cover of the

transformer. It includes an oil cooler, an oil pumping set and the blower of
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the oil cooler. The conservator is fitted to the top of the transformer through
a pipe. At the top of conservator a spring loaded safety valve is fitted.
Above this safety valve, there is an oil overflow chamber with a discharge
pipe which discharges the oil down underneath the locomotive body. The
oil pump and the cooler are both connected to the conservator by a venting
pipe. The air does not come into contact with oil in the conservator directly,
and is dried before by means of a silica gel air dryer.

13. Transformer Tank

The mild steel tank, oil conservator and cooling pipe work are fabricated to
close tolerances to facilitate their mounting in limited space in the
locomotive. In their design, care is exercise to keep their weight down to
bare minimum but at the same time ensuring sufficient strength. The tank
ring and cover are carefully matched to ensure oil tightness under the worst
operating condition encountered during acceleration or retardation of the
locomotive, which brings in additional oil pressure at the joints. The cover
suspended transformer is provided with special screws to adjust the height
of the assembly, so that in fully tighten position it sits evenly on the base
pads.
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14. Some Important Components

14.1. Conservator

It is a drum containing transformer oil and mounted at the top of the

transformer and connected to the main tank by a pipe. As the volume of oil
of transformer tank expands and contracts according to heat produced, this
expansion and contraction of oil causes the level of the oil in conservator to
rise and fall. The aim of conservator is to - Maintains the oil level in tank -
Provides space for the expansion of oil.

14.2. Breather

It is attached to conservator tank and contains silica gel, which prevents

the moist air from entering into the tank during contraction of oil. When oil is
hot there is expansion and gas passes to atmosphere through it. When oil
is cooled, it contracts and the air enters in it. It prevents transformer oil from
moisture contamination.

14.3. Oil level Indicator

It indicates level of insulating oil in the transformer tank. It has

markings on transparent sheet for maximum & minimum levels.

14.4. Inlet Valve

It provides passage to pour the transformer oil in the tank during

purification or in case of shortage found in the tank.

14.5. Outlet Valve

It provides passage to drain the oil during overhauling or as and

when required oil sample for testing.
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15. TESTS
Following common tests to be carried out in the transformer –

15.1. Low Voltage Test –

15.1.1 Insulation resistance test – In this test the resistance of the

insulation of the winding is measured. Measures the insulation resistance
of HV & LV windings with respect to earth (body) and between LV & HV
winding. HV high voltage test : LV winding connected together and earthed.
HV winding connected together and given particular voltage for 1 minute.
INSULATION TESTER OR MEGGER IS USED.

15.1.2 Separate source voltage withstand test - Single phase 50 Hz,

separate source voltage of amplitude as given below shall be applied for 1
minute between each winding to be tested and all other windings
connected together to tank and earth:-

(i) primary winding and all other windings to earth 10 KV

(ii) Traction winding to all other windings and earth 10 KV

(iii) Auxiliary winding to all other windings and earth 6 KV

(iv) Hotel load winding to all other windings and earth 6 KV

15.1.3 Winding resistance test – In this test the resistance of winding is

tested. This test measures the resistance of the HV & LV winding. The
values of resistance should match the designed values. Equipment used :
Digital resistance meter.

15.1.4 Ratio test – Voltage ratio shall be measured between Auto

windings at different taps and both secondary windings. Voltage ratio shall
also be measured between HV winding & Auxiliary winding, & Hotel load
winding .

15.1.5 Pressure & Leakage Test on Tank - Pressure test on the

transformer tank shall be carried out at a pressure of 14.2 PSI over the
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normal head of oil for a period of 24 hours. There shall be no oil leakage
from the tank.

15.2 High Voltage Test –

15.2.1 No load test – In this test core losses are measured. It measures
eddy current losses and hysteresis losses and Stray losses. No load
primary current and losses shall be measured with 50 Hz sinusoidal voltage
applied to high voltage winding. However, this measurement can also be
carried out by energizing Auxiliary/hotel load winding. No load current and
losses for the primary winding shall be measured at 17.5 KV – 27.5 KV in
steps of 2.5 KV.

15.2.2 Short circuit test – In this test copper losses of the transformer is
measured. The losses due to heating of winidng because of high current.

Load losses between HV winding and traction windings, Auxiliary winding

and Hotel load winding shall be measured and corrected to 75°C. The
corrected losses shall not exceed the guaranteed values specified by
manufacturer.

16. FACTORS AFFECTING LIFE OF

TRANSFORMER
Life of transformer is affected by the following factors:

1. Moisture

2. Oxygen

3. Solid Impurities

4. Varnishes

5. Slackness of winding
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17. Finishing

1. Fitting and accessories as per customers specification and drawings

are checked.
2. Air pressure test to conducted to avoid any seepage and leakage on
all the transformer.
3. Fittings like drain valves, HV and LV bushings, conservator , oil level
indicator and explosion vents are fitted in the transformer.
4. Loose accessories like earthing terminals, dial type thermometers are
checked for proper fittings.

18. Replacement of Asbestos

18.1 What is Asbestos?

Asbestos is a naturally occurring mineral substance that can be pulled into

a fluffy consistency. Asbestos fibers are soft and flexible yet resistant to
heat, electricity and chemical corrosion. Pure asbestos is an effective
insulator, and it can also be mixed into cloth, paper, cement, plastic and
other materials to make them stronger.

For all practical purposes most forms of asbestos are inert. That is one
quality that makes them so desirable in industry. They are insoluble in
water and organic solvents and are nonflammable. While the serpentine
chrysotile is soluble in acid, the amphiboles amosite, crocidolite and
anthophyllite are resistant to acids.
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18.2 Why Is Asbestos Dangerous?

Microscopic asbestos fibers cannot be seen, smelled or tasted, and

asbestos exposure does not cause any immediate symptoms, so it is easy
for a person to inhale or swallow asbestos dust without realizing it.

Once asbestos fibers are in the body, they never dissolve, and the body
has extreme difficulty expelling them. Over years of time, trapped asbestos
fibers can cause inflammation, scarring and eventually genetic damage to
the body’s cells.

Asbestos-related illnesses often take 20-50 years to develop, which means

most cases diagnosed in the United States today were caused by asbestos
exposures that occurred before modern safety regulations came into effect.
Occupational exposure is the primary cause of asbestos-related illnesses

18.3 Diseases Caused by Asbestos

Asbestos fibers most often accumulate in lung tissue and in the membrane
lining the lungs called the pleura. Asbestos is a naturally occurring mineral
that has been linked to human lung disease. The three types of asbestos-
related lung disease are scarring (asbestosis), non-cancerous disease of
the tissue of the lining of the surface of the lung (pleural disease), and lung
cancer (of the lungs or their outer lining tissue. Asbestosis is a process of
lung tissue scarring caused by asbestos fibers. Asbestos is the only known
risk factor for malignant mesothelioma, a cancer that affects the tissue
lining the lung (pleura) or abdomen (peritoneum). The time between
exposure to asbestos and the development of cancer can be anywhere
from 10 to 40 or more years.
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18.4 Alternatives to Asbestos

18.4.1 Polyurethane foam is multifunctional, affordably priced and

effective for insulation. Construction workers can quickly and easily apply
spray polyurethane foam to insulate and seal buildings, and manufacturers
frequently use flexible polyurethane foam in consumer products such as
furniture, bedding, carpet cushion, packaging and automotive parts.

18.4.2 Ceramic Fibre is produced from high purity aluminosilicate material

through strictly controlled high temperature furnace melting and fiberizing
process. The fiber is white and odorless, suitable for high temperature
applications up to 2300°F.

Main Characteristics and Specs

Lightweight, low thermal conductivity, high temperature stability, excellent

handling strength, low heat storage, thermal shock resistant, fire and flame
proof, chemical resistant, compatible with most corrosive chemicals,
commonly used acid and alkali (exceptions are hydrofluoric, phosphoric
acids and concentrated alkalis).

Chemical Composition: Al2O3 + SiO2 >97% ( Al2O3 47%); Fe2O3< 1%

Fiber Diameter: 3 – 4.5 microns

Fiber Shrinkage (1800°F, 3h): < 3.5%

Working Temperature : 1,800 °F. for Continuous Use, 2300 °F

Maximum

Specific Heat (@2000°F): 0.27 Btu/lb °F

pH Range: 2-12
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19. Name Plate of Loco Transformer

S. No.-CGPISL-7.775-06-18-BHI0964/05
Frequency -
Phase 1 Year - 2018
50 Hz
Power - 7775 KVA Type Lot - 7775

1U V 25000 V
I 311 A
4x1269/1154(1000)(2x960
2U V
)V
4x1142/347(334)(2x648)
I
A

Oil IEC60296
core and coil 5950 Kg
Quantity of Oil 1600 Kg
Complete Transformer 9950 Kg

Reactor
No.
Phases 1 Type 2 SOD 240
CGTN205391
Power - 2x236.9 KVAr at 50 Hz Frequency - 100 Hz
1 Nom -
L - 2x0.551 mH
2x984 A
2.8 mΩ/75°C
Weight - 585 Kg Loc. Type - WAP 5

Reactor
No.
Phase 1 Type 6 GOD 120
CGTN205392
Frequency - 100 Hz Rip
Power - 3x2x117 KVAr 50 Hz
38.6%
1 Nom -
L - 3X2X13 mH
3x2x155 A
54 mΩ/75° C
Weight - 570 Kg
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20. Conclusion

From this visit, we got the information and practical knowledge about loco
Transformer manufacturing . We got the knowledge about different outer
and inner part of transformer like core, winding and different type of
transformer testing. We came across manufacturing processes. 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.