BHARAT HEAVY ELECTRICALS LIMITED

JHANSI

SUMMER TRAINING - 2018

ROTATIONAL REPORT AND PROJECT REPORT ON
assembling of POWER TRANSFORMER

SUBMITTED TO: UNDER GUIDANCE OF:

DR.AFTAB ALAM. PRABHAT KATIYAR
Sr. D.G.M. (H.R.D.) DY. MANAGER (BAY-9)
BHEL, JHANSI BHEL, JHANSI

SUBMITTED BY:
RAVISHEK KUMAR SINGH
B.TECH 3rd YEAR
ELECTRICAL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY , ARUNACHAL PRADESH
 ACKNOWLEDGEMENT

I am highly thankful and indebted to B.H.E.L. engineers and technical staff for
providing me vital and valuable information about the different facts of an
industrial management system and their respective departments thus helping me to
gain an overall idea about the working of organization.

I am also thankful to Engineers for giving his precious time and help me in
understanding various theoretical and practical aspects of my project on Power
Transformer and their Assembling ,under whose supervision I accomplished my
project.

I would like to thank my parents who have been a constant source of

encouragement & inspiration during my studies & have always provided me
support in every walk of life.

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 PREFACE

At very outset of the prologue it becomes imperative to insist that vocational

training is an integral part of engineering curriculum. Training allows us to gain an
insight into the practical aspects of the various topics, with which we come across
while pursuing our B.Tech i.e. Summer training gives us practical implementation
of various topics we already have learned and will learn in near future. Summer
training always emphasizes on logic and common sense instead of theoretical
aspects of subject.

On my part, I pursue two weeks training at B.H.E.L. Jhansi. The training involved
a study of various departments of the organization as per the time logically
scheduled and well planned given to me.

The rotation in various departments was necessary in order to get an overall idea
about the working of the organization.

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 TABLE OF CONTENT
TITLE PAGE No.
1. About BHEL, Jhansi………………………………………………....6
2. ROTATION REPORT
i. Store.......................................................................................................10
ii. Fabrication…………………………………………………………….10
iii. Bay 3…………………………………………………………………..13
iv. Bay 4…………………………………………………………………..15
v. Bay 5…………………………………………………………………..15
vi. Bay 6…………………………………………………………………..16
vii. Bay 7…………………………………………………………………..17
viii. Bay 8…………………………………………………………………..18
ix. Bay 9 ………………………………………………………………….19
x. Transformer Engineering ……………………………………………...21
xi. Technology………………………………………………………….....22
xii. Transformer Commercial……………………………………………...24
xiii. Locomotive Production..………………………………………………27
xiv. Locomotive Manufacturing……………………………………………27
xv. Locomotive Commercial………………………………………………28
xvi. Central Quality Services ……………………………………………...29
xvii. Testing…………………………………………………………………29
xviii. Work Engineering Services……………………………………………31

3. REPORT ON POWER TRANSFORMER

i. Introduction………………………………………………………..34
ii. Principles of transformers…………………………………..……..34
iii. Losses in transformers……………………………………..……...36
iv. Materials Used in Transformers…………………………………..37
v. Windings and insulations …………………………………….43

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4. CONCLUSION………………………………………………………...45
5. REFERENCES………………………………………………………...46

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 BHARAT HEAVY ELECTRICALS LIMITED
JHANSI
A BRIEF INTRODUCTION
By the end of the fifth year plan, it was envisaged by the planning commission that
the demand for the power transformer would raise in the coming years.
Anticipating the country’s requirement, in 1974, BHEL started a new plant in
Jhansi which would manufacture power and other type of transformer in addition
to the capacity available at BHEL in Bhopal. The Bhopal plant was engaged in the
manufacture transformers of large rating and Jhansi unit would concentrate on
power transformers, instrument transformers, traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the N.H. No 26
on Jhansi Lalitpur road. It is called second-generation plant of BHEL set up in
1974 at an estimated cost of Rs 16.22 crores inclusive of Rs 2.1 crores for
township. Its foundation was laid by late Mrs. Indira Gandhi the prime minister on
9th Jan. 1974. The commercial production of the unit began in 1976-77 with an
output of Rs 53 lacs since then there has been no looking back for BHEL Jhansi

The plant of BHEL is equipped with most modern manufacturing processing and
testing facilities for the manufacture of power, special transformer and instrument
transformer, Diesel shunting locomotives and AC/DC locomotives. The layout of
the plant is well streamlined to enable smooth material flow from the raw material
stages to the finished goods. All the feeder bays have been laid perpendicular to the
main assembly bay and in each feeder bay raw material smoothly gets converted to
sub assemblies, which after inspection are sent to main assembly bay.

The raw material that are produced for manufacture are used only after thorough
material testing in the testing lab and with strict quality checks at various stages of
productions. This unit of BHEL is basically engaged in the production and
manufacturing of various types of transformers and capacities with the growing
competition in the transformer section, in 1985-86 it under took the re-powering of
DESL, but it took the complete year for the manufacturing to begin. In 1987-88,
BHEL has progressed a step further in under taking the production of AC
locomotives, and subsequently it manufacturing AC/DC locomotives also.

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PRODUCT PROFILE OF B.H.E.L., JHANSI

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LAYOUT PLAN OF B.H.E.L. JHANSI

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ROTATION
REPORT

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 MAIN AIM OF ROTATION
Main aim behind the rotation of various departments is that one can understand the working of
each an devery department and to see that how people (workers, middle level executives, top
officials) work incorporate environment.
Main departments of BHEL Jhansi are
 Production
 Administration

PRODUCTION UNIT DEPARTMENTS

1. STORE :
It is one of the prime departments of material management department.
There are separate stores for different type of material in the BHEL.
There are three sections in store:
 Control Receiving Section
 Custody Section
 Scrap Disposal Section.

2. FABRICATION :

Fabrication is nothing but production. This shop deals with the manufacturing of
transformer and locomotive components such as tanks, plates and nuts & bolts. It
comprises of three bays i.e. Bay 0, Bay 1 and Bay 2.
A. Bay 0 :
This is the preparation shop where according to the required drawings, the cutting of
different components of different materials is done. This section has the following
machines:
 Planer machine – It is used to reduce thickness.
 Cutting machine --
o CNC/ANC Flame cutting machine – To cut complicated shaft using Oxy-
Acetylene flame. This is fully computerized. The figure is loaded into a computer
attached to machine and flame thus cuts figure accordingly.
o Pantograph flame cutting machine.
o PUG cutting
 Shearing machine- This machine is used for metal sheet. Cutting range is 2mm to 6mm.
Suitable materials for use are Al, Standard steel and Cu. It cuts material just like a
scissor.
 Flattening machine-It is used to straighten or to flattening the job using power hammer.

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  Radial Drilling machine- In this machine, tool can move radically. In this cutting oil
mixed with water is used to cool the drill tool is used as the material to be drilled.
Different drill tools are used from 2mm to 100mm dia.
 Nibbling machine- Used for straight cutting, circle cutting, nibbling, circular and square
punching.
B. BAY 1 :
It is an assembly shop where different parts of tank come from bay 0. Here welding
processes are used for assembly, after which a rough surface is obtained which is
eliminated by Grinder operating at 1200 rpm.

C. BAY 2 :

It is also assembly shop dealing with making different object mentioned below:

 Tank assembly
 Tank cover assembly
 End frame assembly.
 Foot assembly.
 Cross feed assembly.
 Core clamp assembly.
 Pin and pad assembly.

3. TRM BAY – 3 :
It is split in two parts, half consists of machine shop and the other half consists of winding of dry
type transformer.
Here are basically three sections:
1. Machine Section.
2. Copper Section.
3. Tooling Section.

a. MACHINE SECTION :
The operations to form small components of Power & Traction Transformers are done in section.
The shop consists of following machines:
1. Lathe machine
 Central lathe machine- It consist one tailstock, headstock low part of tailstock is fixed
& tailstock spindle is moving. On this machine facing, turning & threading is done. It is
used for light work and its range is 20mm to 200mm.
2. Radial arm drilling machine-It is used for drilling & boring.
3. Horizontal boring machine-It is computerized and used for making bore, facing etc.
4. Milling machine:
 Horizontal milling machine – It is used for making gear and cutting operations.
 Vertical milling machine – By this machine facing, cutting & T slot cutting is done

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5.Grinder:
 Tool cutter grinder- Used for cutting tools and also grind them.
 Hydraulic surface grinder- It consist of magnetic platform. Cooling oils are used as
coolant.
 Vertical grinder machine-Used for grinding purpose.
6. Hydraulic power press- Used for straightening the material. The capacity of this machine is
25 tons.
7. Resistance brazing machine- used for overlap connections.
b. COPPER SECTION :
This part is only with copper cutting, bending, tinning etc.Machine used are as listed below.

Tube slitting machine-This machine is developed here & is used for cutting the tube along its
length & across its diameter. Its blade thickness is 3 mm.

Shearing machine-It is operated hydraulically & its blade has V-shape & a thickness of 15 mm.

Die and punching machine-It is also hydraulically operated & has a die & punch for making
holes.

Hydraulic bending machine-It is used for bending job up to 90 degree.

Fly press machine- It is used to press the job. It is operated mechanically by a wheel, which is
on the top of the machine.

Bend saw machine -This machine is used for cutting job having small thickness. It is circularly
operated blade, around 1.5 m long.

Water cooled brazing machine-It contain two carbon brushes. The sheet is put along with a
sulfas sheet & the carbon brushes are heated. A lap joint is formed between the sheets as the
sulfas sheet melts.

Linking belt machine- It creates a smooth surfaces.

Hydraulic press machine-To press the job.

Solder pot machine-It has a pot that contains solder. Solder has a composition of 60% Zn &
40% Pb.

c. TOOLING SECTION:
In this section the servicing of tools is done.

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Blade shape machine-It sharpens the blade using a circular diamond cutter. Blade of CNC,
cropping line machine is sharpened here.
Mini surface grinder machine-It serves grinding purposes. It has a grinding wheel made of
Aluminium Oxide.
Tool & surface grinding machine-This is specially used to grind the tool used in Bay 7.
Drill grinding machine-To grind the drills.

4. TRM BAY 4 &11:

It is the power transformer winding section.

TYPES OF WINDING
1) Reverse section winding.
2) Helical winding
3) Spiral winding.
4) Interleaved winding.
5) Half Section winding
There are four types of coils fixed in a transformer.
1) Low voltage coil (LV)
2) High voltage coil (HV)
3) Tertiary coil.
4) Tap coil.

The type of winding depends on job requirement also the width and thickness of the conductors
are designed particulars & are decided by design department. Conductors used for winding is in
the form of very long strips wound on a spool, the conductor is covered by cellulose paper for
insulation.
For winding, first the mould of diameter equal to inner diameter of required coil is made. The
specifications of coils are given in drawing. The diameter of is adjustable as its body is made up
of wooden sections that interlock with each other. Interlocking can be increased or decreased to
adjust the inner diameter of coil.

The Moulds are of following types:

1. Belly types.
2. Link types.
3. Cone types.

5. TRM BAY 5 :
It is core and punch section. The lamination used in power, dry, ESP transformer etc. for making
core is cut in this section.

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 CRGO (Cold rolled grain oriented) silicon steel is used for lamination, which is imported in
India from Japan, Korea, U.K. or Germany. It is available in 0.27 & 0.28 mm thick sheets, 1 m
wide & measured in Kg. The sheets are coated with very thin layer of insulating material called
“carlites” to avoid short circuiting.
Core is the basic requirements of transformer in this bay various type of lamination of core is
made, they are:
a) Side leg- this lamination is at the extreme ends of the core which stand vertical. They are
isosceles trapezium in shape with angle of 45o.
b) Central leg- This as the name suggests is central vertical portion of the core. It is a
diamond shaped with vertical edges longer. At the narrower edge one side is kept longer
than the other for making a well fixed joint; the angles are kept 450.
c) Yoke- The horizontal lamination of the core is called yoke. They are also isosceles
trapezium in shape with angles of 450.

Core
Transformer
CRGO sheet

6. TRM BAY 6 :
4 different types of Transformers are manufactured in this section :
i. 3-phase Freight loco Traction Transformer
ii. 1-phase Freight loco Traction Transformer
iii. 3-phase ACEMU
iv. 1-phase ACEMU

Single – traction transformer for AC locomotives is assembled in this section. These Freight
locomotive transformers are used where there is frequent change in speed. They are basically
used in locomotives. In this bay core winding & all the assembly & testing of transformer is
done.

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These three phase transformer for ACEMU are also manufactured in this section. The supply
lines for this transformer are of 25 KV & power of the transformer is 6500 KVA.

The tap changer of rectifier transformer is also assembled in this bay. Rectified transformer is
used in big furnace like the thermal power stations/plants (TPP).

7. TRM BAY 7 :
This is the insulation shop. Various types of insulation which are to be used in
transformers are prepared in this bay.

MATERIALS USED:
1) AWWW: All Wood Water Washed press paper.The paper is 0.2-0.5 mm thick cellulose
paper & is wound on the conductors for insulation.
2) Pre-compressed board: This is widely used for general insulation & separation of
conductors in the forms of block.
3) Press board: This is used for separation of coils e.g. L.V. from H.V. It is up to 38 mm
thick.
4) UDEL: Undemnified Electrical Laminated Wood or Perm wood. This is special type of
plywood made for insulation purposes.
5) Fiber glass: This is a resin material & is used in fire prone areas (Used in DTT)
6) Bakelite: Size 4mm to 25 mm.
7) Gasket: It is used for protection against leakage.
8) Silicon rubber: It is used for dry type transformer.
9) Perma wood: Size 4mm to 25mm.
10) N.B.C. (Naporeniom Bonded Cork) sheets: Size 3mm, 6mm 10mm and 12mm.
8. TRM BAY 8 :
Basically two types of transformers are assembled in this bay:
1) Electrostatic Precipitator (ESP)
2) Instrument Transformers
a) Current Transformer (CT) up to 400kV class.
b) Electromotive Voltage Transformer (EMVT) up to 220kV class.

INSTRUMENT TRANSFORMER:

These are used for measurement. Actual measurement is done by measuring instruments but
these transformers serve the purpose of stepping down the voltage to protect the measuring
instrument. They are used in AC system for measurement of current voltage and energy and

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can also be used for measuring power factor, frequency and for indication of synchronism.
They find application in protection of power system and for the operation of over voltage, over
current, earth fault and various other types of relays.

In power lines current & voltage handled is very large & therefore direct measurement are not

a) Current transformer: It is a step down transformer. The body is divided in to three parts
– top chamber, bushing, bottom chamber. Top chamber is the cylindrical tank of mild
steel. It has terminal for connection of HV coil. It also has oil window to indicate the oil
level. Below it is bushing which houses the winding and also act as insulator. It has
several folds or rain sheds to provide specific electric field distribution and long leakage
path. Some bushings are cylindrical while modern ones are conical, as the amount of oil
porcelain used is reduced without any undesirable effects. Bottom chamber houses the
secondary winding. There is also a connection box to which the connection of low voltage
coil is made.

b) Voltage Transformer: It is also an step down transformer and outer construction is same as
that of CT. the difference is only in winding.

ESP TRANSFORMER:

The Electrostatic Precipitator transformer is used for environmental application. It is used to

filter in a suspended charge particle in the waste gases of an industry. They are of particular use
in thermal power stations and the ash is used in cement industry.

It is also known as Rectifier Transformer as it converts AC into DC.

9. TRM BAY 9:
In this bay, power transformers are assembled. After taking input from different bays 0-8,
assemblies are done.
Power Transformer is used to step up & step down voltages at generating & sub-stations. There
are various ratings 11 KV, 22 KV etc. manufactured, they are:
a) Generator Transformer
b) System Transformer
c) Auto Transformer

A transformer in a process of assemblage is called a job. The design of the transformer is done
by the design department & is unique for each job; depends on the requirement of customer. The
design department provides drawing to the assembly shop, which assembles it accordingly.
The steps involved in assembly are:

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 10. TRE (TRANSFORMER ENGINEERING):
The transformers manufactured in BHEL Jhansi range from the 100MVA to 315MVA and up to
400kV.The various transformers manufactured in this unit are:
Power Transformer
 Generation transformer
 System transformer
 Auto transformer

Special Transformer
 Freight loco transformer
 ESP transformer
 Dry Type Transformer

All above types are oil cooled except dry type, which is air cooled.

The designing of all these transformers is done by the TRE department according to the
specifications of the customers’ i.e.
1. The input/output voltage.
2. The KVA rating.
3.The weight of iron and copper.
The basic design factors are:
1. The amount of copper and iron losses.
2.The rise in temperature of coils.
3.The ambient condition.

11. TECHNOLOGY:
This department analysis the changes taking place in the world and suggest changes and
upgrades accordingly. This section mainly deals with continuous modification in the operations
to be performed for the completion of the job. It gets the PSR (Performa of Specification &
routine Sheet) from PPC.
This is very important department because the product must not get obsolete in the market
otherwise they will be rejected by the customer.

This section gives the sequence of operations, time for operations, no. of labors etc., according to
the given standards; it can be modify the above things to obtain best results.

BUS DUCT :

Bus ducts are conductors for high power application. They are used in power connections over
150 MW. The bus ducts consist of a mild steel casing and Aluminium conductors held within the

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casing with electro-porcelain insulators. The bus ducts are installed with hot air blowing fans to
keep the conductors moisture free at the time of operation. Two types of bus ducts are
manufactured:

 Segregated Bus Ducts (SBD)

 Isolated Bus Ducts (IBD)

In segregated bus ducts , one casing is divided into three chambers through which Aluminium
conductors for three phases pass.

In isolated bus ducts, each phase is provided with its own casing. The bus ducts also have
cubicles in which circuits and controls are installed.

The mild steel casings of bus ducts are mostly procured as pre-fabricated items. Aluminium bars
are also main raw material for the manufacturing of bus ducts.

12. TRC (TRANSFORMER COMMERCIAL):

The objective of this department is to interact with the customers. It brings out tenders & notices
& also responds to them. It is department that places the contracts of building the transformers &
after delivery further interacts with the customer regarding faults, this department does failure &
maintenance. All such snags are reported to them & they forward the information to the
concerning department.

LOCOMOTIVE DEPARTMENT

This unit was started in 1985.

A locomotive is a rail vehicle that provides the motive power for a train.
“LOCO” means from a place.
“MOTIVE” means causing motion.
A locomotive has no payload capacity of its own. It is used to move a train.
This department of Jhansi consists of two sections the first is manufacturing & other is design.
The diesel, AC, AC/DC locomotives are manufactured here.

1. THE DIESEL LOCOMOTIVE:

Salient features:
a) Flat bed under frame.
b)All pneumatic valves provides in single panel.
c)All electrical Equipments provided in single panel.
d)Improved filtration system.
e)Brush less traction alternators.

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f)Fault display on control desk with alarm.
g)Simple driving procedure.
h)Automatic wheel slip detection & correction.
i)Multiple unit operation up to three locomotives.
j)Air & vacuum brakes.

2. THE AC LOCOMOTIVE
Salient features:
a)Operate on 25 KV AC Single-phase lines.
b)Driving cab at both ends.
c)Corridors on both sides for maintenance.
d)All pneumatic valves at one place.
e)Automatic wheel slip detection & correction.
f)Multiple unit operation up to three locomotives.
g)Fault display on driver’s desk.
h)VCB in AC circuit.
i)Air & Vacuum brakes.

3. THE AC/DC LOCOMOTIVE

Salient features:
a) Designed to operate both in 1500 V DC & 25 KV AC lines.
b) Driving cab at both ends.
c) High adhesion bogie.
d) Corridors on both sides for maintenance.
e) All pneumatic valves at one place.
f) Automatic wheel slip detection & correction.
g) Multiple unit operation up to three locomotives.
h) Fault display on driver’s desk.
i) Static inverter for auxiliary supply.
j) FRP control desk.
k) VCB in AC circuit.
l) Air & Vacuum brakes.
m) Air dryer for brake system.

13. LOCOMOTIVE PRODUCTION (LMP):

There are following products are manufactured at Loco shops

 Alternating Current Locomotive (ac Loco)

 WAG-5H
 AC./D.C. Loco
 WCAM-2P
 WCAM-3
W-broad gauge A-running in AC mode

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C-running in DC mode G-hauling goods train
P-hauling passenger train M-hauling passenger& goods train

14. LMM (LOCOMOTIVE MANUFACTURING):

This section deals with manufacturing of locomotives. The main parts of the
locomotive are -
 Under frame: The frame on which a locomotive is built
 Super structure: The body of locomotive is called superstructure or Shell and is made of
sheet of Mild steel
 DC motor
 Alternator
 Compressor: When air pressure is 5kg/cm2 , it will lift up pantograph.
 Flower
 B.D.Panel : It will control and power low power equipments.
 Static Rectifier-MSR : converts 1-phase AC supply to 110V DC to charge battery.
 Static Converter-SC : converts 1-phase 1000V AC supply from overhead
extension(OHE) to 3-phase 440V AC supply .
 Exchanger
 Blower-MVMT : It will suck air through 3 ducts. These ducts are directly connected to
Traction motor for cooling it.
 ATFEX : It is braking transformer.
 Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially contains

15. LMC (LOCOMOTIVE COMMERCIAL):

This department is divided into 3 sections :

a) Tendering
b) Execution
c) Service after sales

The Tendering section Looks upon requirements of customer , estimate cost of project and
other information of tender. On receipt of tender forms formal tender enquiries are issued to
engineering dept., production planning and control , central dispatch cell. If tender is technically
acceptable then offer is submitted to customer. Offer includes technical , commercial details and
other terms and conditions. On opening of technical bid the commercial bid of technically
qualified tenderers is opened and order is placed on lowest value tender.

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 16. CQS (CENTRAL QUALITY SERVICES) :
First we get acquainted with a few terms concerning this department.
Quality: It is the extent to which products and services satisfy the customer needs.
Quality Assurance: All those plants and systematic action necessary to provide adequate
confidence that a product or service will satisfy the given requirement is called quality
assurance.
Quality control: The operational techniques and activities that are used to fulfill
requirement for quality are quality controlled.
Quality Inspection: Activities such as measuring, testing, gauging one or more
characteristics of a product or service and comparing these with specified requirements to
determine conformity are termed as Quality Inspection.

17. TESTING :
In this shop testing on the transformer is carried out in one section and for loco in other section.
In transformer testing section there are for MG sets. The electrical specifications of the entire test
are given. These tests are done on demand of customer on transformer manufactured.

Here basically there are basically following tests conducted on power transformers:

1. ROUTINE TEST- It is conducted on all transformers. They are:

a) Ratio test: To determine the Voltage Transformation ratio on each tapping between HV
and LV.
b) Vector Group: To verify the internal connection of the coils(Windings) and the
connection to the terminal.
c) Winding Resistance measurement: To check the healthiness of various joints, internal
connection of the coil and connection to the terminals/Bushings.
d) Magnetizing Current: To measure No load current at low voltage (Supply voltage)
e) Magnetic Balance: To measure flux distribution in each winding by exciting (by applying
voltage)one winding only.
f) Insulation Resistance measurement: To check the healthiness of the insulations provided
on each winding in turn to all other windings, core and frame or tank.
g) Separate source test: To check the healthiness of the insulation of each winding in turn to
all other windings, core and frame or tank with applies single phase voltage.
h) No-load loss measurement: To calculate the Power consumption during No load
condition of the Transformer itself.
i) Load loss & impedance measurement: To calculate the Power consumption during full
Load condition of the Transformer itself.

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 j) Induced overvoltage test: To verify the A.C. voltage withstands strength of each line
terminal and it’s connected winding to earth and other windings, withstand strength between
phases and along the winding under test.
k) 02 KV core isolation test: To check the isolation of core.

2. TYPE TEST- These are to be conducted only on one unit of same design.
a) Temperature rise test: To observe the maximum temperature when the transformer is
running on continuous full load.
b) Impulse test: To verify the A.C. voltage withstands strength of each line terminal and it’s
connected winding to earth and other windings, withstand strength between phases and along
the winding under test. This test is conducted at a voltage even higher than induced
overvoltage.
c) Auxiliary loss test: To measure the power taken by cooling gear like Fans & pumps.
d) Acoustic Noise level measurement: To measure average sound level generated by the
Transformer when energized at rated voltage and rated frequency at no load.
e) Zero sequence impedance measurement: To calculate the impedance when all three
phase are symmetric.
f) Short time current test (STC test)

18. WE&S (WORK ENGINEERING AND SERVICES) :

As the name suggest this section deals with services & maintenance. It has following sections:
a) Plant equipment: This has electronics & elect/mech. Maintenance.
b) Services: This section deals with air, steam & Power equipments.
c) Telephone Exchange.
d) Township Electrical Maintenance.
e) W.E. & S Planning.

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 REPORT ON
ASSYMBLY OF
POWER
TRANSFORMER

INTRODUCTION:
A transformer is a static machine used for transforming power from one circuit to another
without changing frequency. This is very basic definition of transformer. Transformer generally
used in transmission network is normally known as Power Transformer. The term 'Power
Transformers’ refers to the transformers used betweenthe generator and the distribution circuits,
and these are usually rated at 500 kVAand above. Power systems typically consist of a large
number of generationlocations, distribution points, and interconnections within the system or
with nearbysystems, such as a neighbouring utility. The complexity of the system leads to

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avariety of transmission and distribution voltages. Power transformers must beused at each of
these points where there is a transition between voltage levels.
Power transformers are selected based on the application, with the emphasistoward custom
design being more apparent than larger the unit. Power transformersare available for step-up
operation, primarily used at the generator and referred toas generator step-up (GSU)
transformers; step-down operation, mainly used endto feed distribution circuits and to connect
grids operating at different voltage levels through interconnecting transformers. Power
transformers are available as single-phaseor three-phase apparatus.
Power transformers have been loosely grouped into three market segments basedon size ranges.
These three segments are:
1. Small power transformers 500 to 7500 kVA
2. Medium power transformers 7500 to 100 MVA
3. Large power transformers 100 MVA and above.

WORKING PRINCIPLE:
The working principle of transformer is very simple. It depends upon Faraday's law of
electromagnetic induction. Actually mutual induction between two or more winding is
responsible for transformation action in an electrical transformer.

In its simplest form,a transformer consists of two conducting coils having a mutual inductance.
Theprimary is the winding which receives electric power, and the secondary is the onewhich
may deliver it. The coils are wound on a laminated core of magnetic material.
The physical basis of a transformer is mutual inductance between two circuitslinked by a
common magnetic flux through a path of low reluctance.
The two coils possess high mutual inductance. If one coil is connected to asource 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 inducedemf (electromotive force) according to Faraday's
laws electromagnetic induction,i.e.
𝒅𝒊
e=𝑴 𝒅𝒕
where, e = induced emf
M = mutual inductance
If the second circuit is closed, a current flows in it and so electric energy istransferred (entirely
magnetically) from the first coil (primary winding) to the secondcoil (secondary winding).

MAIN CONSTRUCTIONAL PARTS:

1. Primary Winding of transformer - which produces magnetic flux when it is connected to
electrical source.
2. Magnetic Core of transformer - the magnetic flux produced by the primary winding, will pass
through this low reluctance path linked with secondary winding and creates a closed magnetic
circuit.
3. Secondary Winding of transformer - the flux, produced by primary winding, passes through
the core, will link with the secondary winding. This winding is also wound on the same core and
gives the desired output of the transformer.

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USE OF POWER TRANSFORMER:
Generation of Electrical Power in low voltage level is very much cost effective. Hence Electrical
Power is generated in low voltage level. Theoretically, this low voltage leveled power can be
transmitted to the receiving end. But if the voltage level of a power is increased, the electric
currentof the power is reduced which causes reduction in ohmic or I2R losses in the system,
reduction in cross sectional area of the conductori.e. reduction in capital cost of the system and it
also improves the voltage regulation of the system. Because of these, low leveled power must be
stepped up for efficient electrical power transmission. This is done by step up transformer at the
sending side of the power system network. As this high voltage power may not be distributed to
the consumers directly, this must be stepped down to the desired level at the receiving end with
help of step down transformer. These are the use of electrical power transformer in the Electrical
Power System.

THREE WINDING TRANSFORMER:

A transformer may have additional windings apart from the two conventionalmain windings
depending upon the particular application and type of connection(of the main windings). In
three-winding transformers, the third winding is normallycalled as tertiary winding and it is
provided to meet one more of the followingrequirements:
(a) For an additional load which for some reason must be kept isolatedfrom that of secondary.
(b)To supply phase-compensating devices, such as condensers,operated at some voltage not
equal to primary or secondary or withsome different connection (e.g. mesh).
(c) In star/star-connected transformers, to allow sufficient earth faultcurrent (zero-sequence
component current) to flow for operation ofprotective gear, to suppress harmonic voltages
and to limit voltageunbalance when the main load is asymmetrical, the tertiary windingis
delta-connected.
(d) As a voltage coil in a testing transformer.
(e) To load charge split winding generators.
(f) To inter-connect three supply systems operating at different voltages.

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MATERIALS USED IN TRANSFORMERS:

Apart from active materials like copper and cold rolled grain oriented siliconsteel, a number of
ferrous, nonferrous and insulating materials are employed forbuilding up a transformer.
Optimum utilization of all materials in consonance withtheir electrical, mechanical, physical,
chemical and thermal characteristics isnecessary for obtaining a compact size transformer. One
basic requirement for allmaterials used in an oil-filled transformer is that they should be
compatible withinsulating oil and should not react with or deteriorate oil.
Table 1 gives application, applicable national and international standardsof various materials
used in a transformer.
INSULATING OIL:
Insulating oil in an electrical power transformer is commonly known as Transformer Oil. It
isnormally obtained by fractional distillation andsubsequent treatment of crude petroleum. Thatis
why this oil is also known as Mineral InsulatingOil. Transformer Oil serves mainly twopurposes
one it is liquid insulation in electrical power transformerand two it dissipates heat ofthe
transformer i.e. acts as coolant. In addition tothese, this oil serves other two purposes, it helpsto
preserve the core and winding as these arefully immersed inside oil and another
importantpurpose of this oil is, it prevents direct contact ofatmospheric oxygen with cellulose
made paperinsulation of windings, which is susceptible tooxidation.The basic raw material for
the production oftransformer oil is a low-viscosity lube termed as transformer oil base stock
(TOBS),which is normally obtained by fractional distillation and subsequent treatment ofcrude
petroleum. Important characteristics of TOBS given in Table 2 must be keptwithin permissible
limits in order to produce good insulating oils. TOBS is furtherrefined by acid treatment process
to yield transformer oil.

The parameters of Transformer Oil are categorized as:

1. Electrical Parameters – Dielectric Strength , Specific Resistance, Dielectric Dissipation Factor.
2. Chemical Parameter - Water Content, Acidity, Sludge Content.
3. Physical Parameters - Inter Facial Tension, Viscosity, Flash Point, Pour Point.

WINDINGS IN POWER TRANSFORMER:

Windings form the electrical circuit of a transformer. Their construction shouldensure safety
under normal and faulty conditions. The windings must be electricallyand mechanically strong to
withstand both over-voltages under transient surges,mechanical stress during short circuit and
should not attain temperatures beyondthe limit under rated and over-load conditions. For core-
type transformers, thewindings are cylindrical, and are arranged concentrically. Circular coils
offer thegreatest resistance to the radial component of electromagnetic forces, since thisis the
shape which any coil will tend to assume under short circuit stresses.
The windingsconsist of the current-carrying conductors wound around the sections of the core,
and these must be properly insulated, supported and cooled to withstand operational and test
conditions.
Copper and aluminum are the primary materials used as conductors in power-transformer
windings. While aluminum is lighter and generally less expensive than copper, a larger cross

~ 26 ~
section of aluminum conductormust be used to carry a current with similar performance as
copper. Copper has higher mechanical strength and is used almost exclusively in all but the
smaller size ranges, where aluminum conductors may be perfectly acceptable. In cases where
extreme forces are encountered, materials such as silver-bearing copper can be used for even
greater strength. The conductors used in power transformers are typically stranded with a
rectangular cross section.
In core-form transformers, the windings are usually arranged concentrically around the core leg.

TYPES OF WINDINGS
The choice of the type of windings is largely determined by the rating of thewinding. Some of
the common types of windings are described below.

1. SPIRAL WINDING
This type of winding is normally used up to 33 kV and low current ratings.Strip conductors are
wound closely in the axial direction without any radial ductsbetween turns. Spiral coils are
normally wound on a bakelite or pressboard cylinder(Fig. 3).

Fig.3.Spiral coil (single layer, wound on flat side)

Though normally the conductors are wound on the flat side, sometimesthey are wound on the
edge. However, the thickness of the conductor should besufficient compared to its width, so that
the winding remains twist-free (Fig. 4)

Fig.4.Spiral coil (edge wound)

Spiral windings may be made as single layer or multilayer type. In a double-layer spiral coil
where oil duct separates the two layers. Forsuch a coil, both the start and the finish leads lie at
one end of the coil and may attimes prove to be advantageous for making the terminal gear.
Normally it is not necessary to provide any transposition between the parallelconductors of a
spiral winding as the lengths and the embracing of leakage fluxare almost identical.

2. HELICAL WINDING
This type of winding is used in low-voltage and high-current ratings. A numberof conductors are
used in parallel to form one turn. The turns are wound in a helixalong the axial direction and
each turn is separated from the next by a duct. Helicalcoils may be single-layer (fig. 5) or double
layer (fig. 6) or multi-layer, if the numberof turns is more.

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 Fig.5.Helical coil (Single layer) Fig.6.Helical coil (Double layer)

3. CONTINUOUS DISC WINDNG OR R-S COIL

This type of winding is used for voltage between 33 and 132 kV and mediumcurrent ratings.
These coils consist of a number of sections placed in the axialdirection (fig. 7), with ducts
between them. Each section is a flat coil, having morethan one turn, while each turn itself may
comprise one or more conductors (usuallynot more than four or five), in parallel. The sections
are connected in series, butwithout any joints between them. Thisis achieved by a special method
of winding.It is not necessary to provide a cylindrical former for these coils, as these are
selfsupporting.Each disc is mechanically strong and exhibits good withstand of axialforces. The
layer depth or LD of the winding is defined as the number of turns of segments available in the
section. Another particular advantage of these coils is that, each section can haveeither integral
4
or fractional number of turns (for example 15 18turns per section). Once the number of turn is
given, rest of the segment in that section is provided with packing to maintain LD.

This is also known as R-S or reverse section coil because one section is given the reverse
winding while one section is given forward winding.

4. HALF SECTIONAL COIL

~ 28 ~
These kinds of coils can be classified on the basis of winding direction, if the winding is started
by rotation of conductors in clockwise direction i.e. known as standard half sectional coil
whereas anticlockwise rotation is termed as non-standard half sectional coil. The brazing leads
required in some cases of the transformer are also provided in this kind of coil.

TERMS CONNECTED WITH WINDING

 Transposition- In order to make the length of all the conductors in a winding, the
position of each conductor is varied symmetrically. This is known as transposition.
Unless transposed, the conductors within a coil do not have the same length and same
flux embracing and therefore have unequal impedance, resulting in eddy losses due to
circulating current between the conductors in parallel. To reduce these eddy losses, the
helical windings are provided with transposition of the conductors which equalise the
impedances of the parallel conductors.

 ID-This is known as the inner depth or diameter of the coil. This is basically the width of
the base on which the conductors are wounded.

 OD-This is known as outer depth or diameter of the coil.

 LD-It is known as layer depth.

 CD-It is known as CD. It is the length measured from starting lead point to the finishing
lead point.
 MD-This is known as mould diameter and is same as ID.

~ 29 ~
Fi

MAGNETIC CIRCUIT
In a transformer, energy is transferred from one electrical circuit to anotherthrough the magnetic
field. Transformer core made of laminated sheets providesthe magnetic circuit for the flow of
magnetic flux mutually linking the electricalcircuits. As against the air core, iron core provides a
comparatively low reluctancepath to the magnetic flux with consequent benefit of
(a) Smaller magnetizing current,
(b) Increase in the total flux linkage and
(c) A high ratio of mutual to leakage fluxresulting in reduction of stray losses.
Its design, type and manufacturing methodshave significant bearing on quality, transportability,
operational limitations andguaranteed technical performance of the transformer.

MATERIAL
CRGO (Cold Rolled Grain Steel) is used to build the core. Ithasthe minimum Epstein losses to
the flow of magnetic flux alongthe directions of grain orientation. CRGO is used to reduce the
hysteresis losses and the lamination made out of these sheets minimizes the eddy’s current
losses.Both surfaces of the core steel sheets are providedwith an insulating of oxide coating
(commercially known as Carlite). The stackingfactor of lamination improves by using thicker
laminations, but eddy current lossgoes up in proportion to square of the thickness of the
lamination. For reducingthe eddy current losses, thinner laminations are preferable even though
the stackingfactor goes down. Deburring of the laminations improves the stacking factor
andminimizes the eddy losses.

DESIGN OF MAGNETIC CIRCUIT

~ 30 ~
For a transformer design, the basic governing factors are:
(a) Rating of transformer and its performance.
(b) Operational conditions,
(c) Transport limitations (i.e. height, length, width and weight etc.)
The design of the magnetic circuit, i.e. transformer core is also based onthe above considerations
and it has significant bearing on the overall economy ofthe transformer. For CRGOS, saturation
may occur at the magnetic flux densitiesexceeding 1.9 tesla. Based on the input voltage and
frequency variations, a suitablevalue of flux density can be adopted to avoid any chance of core
saturation underoperating conditions. By increasing the operating value of magnetic flux
density(magnetic loading) the net weight of core can be reduced, but this leads tocorresponding
increase in the core losses. One has to compute an optimum valueof the magnetic flux density,
keeping in view all the above considerations.
Constructional Features
The type of transformer core construction depends on the technical particulars of the transformer
and transport considerations. In general it is preferable to accommodate the windings of all the
three phases in a single core frame. Three phase transformers are economical over a bank of
three single-phase transformers.
Another important advantage of three-phase transformer cores is that component of the third and
its multiple harmonics of mmf cancel each other, consequently thesecondary voltage wave shape
are free from distortions due to the third harmonics in mmf . However, if the three-phase ratings
are large enough and difficult to transport, one has no choice but to go for single-phase
transformer units.
For single-phase and three-phase transformers, the cores can be broadlyclassed as:
(a) Single-phase three-limbed core
(b) Single-phase two-limbed core
(c) Three-phase three-limbed core
(d) Three-phase five-limbed core

CRGO CUTTING
BURR LEVEL: The sheets undergo proper cutting and is then available in many shapes like
trapezoidal, octagonal, hexagonal etc. But while cutting the edges of these sheets, there is some
generation of rough surfaces which are known as burr level. The formation of these levels should
be avoided because they produces air gap which increases the losses. To control the burr level,
the cutting of CRGO is done with the help of CNC(Computer Numeric Control) machines.

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 Fig.12. CNC and core assembly

CORE ASSEMBLY
Core building from the finished lamination sheets is done in horizontalposition on specially
raised platforms. The lamination sheets are susceptible tomechanical stresses of bending,
twisting, impact, etc. A lot of care is exercisedwhile handling and normally two persons are
needed to hold the two ends of thelaminations at the time of laying.
At first the clamp plates and end frame structure of one side of the coreassembly are laid out.
Guide pins are used at suitable positions for maintainingthe proper alignments during core
building process. Oil ducts are formed by stickingstrips on lamination and put in position as
required.

For each packet, the laminations are manufactured in two different lengthsand these sets are laid
out alternately, keeping at a time two to four laminationstogether. The two alternate

~ 32 ~
arrangements provide overlapping at the corner jointsand when the lamination packets are
clamped together, these overlapping edgesprovide sufficient mechanical strength in holding the
edges in tight grip. After layingout the complete laminations, the clamp plates, and end frame
structure of theother side are laid out and the entire core-end frame structure is properly
securedthrough bolts and steel bands at a number of positions.

The platform on which the core building takes place is of special designand the core-end frame
assembly can be raised to the vertical position alongwiththe platform which serves as a cradle.
Subsequently the platform is disengaged.
In this process, the core assembly is spared from the mechanical strain of liftingand raising in the
vertical position. Small-size cores can however be built up withoutthese special platforms.
Steel bands used for tightening the laminations is only a temporaryarrangement and are later
removed, otherwise these will form short circuited turns.

Two commonly used methods of holding the leg laminations together is their clamping by either
resiglass tape or using skin stressed bakelite cylinders.

In case of resiglass tapes, these are tightly wound around the legs at specifiedpitch and cured by
heating. The tape shrinks after heating and provides a firmgrip. The tensile strength of resiglass
tapes is even higher than that of steel tapes.

In the case of core legs tightened by skin stressed cylinders (base cylinder ofinnermost coil),
these are lowered from the top and the steel bands and cutprogressively. Wooden wedges are
inserted along the packet corners andhammered down, so that the enveloping bakelite cylinder
and the leg laminationsare fitting tightly against each other.

Conventionally, the core is assembled along with all the yokes, and afterassembly the top yokes
are unlaced after removing the top-end frames for thepurpose of lowering the windings. This
takes a lot of labour and manufacturingtime. The latest development is to assemble the core
without top yokes and insertthe top yokes after lowering all the windings in the core leg.

~ 33 ~
 Fig.13. Core assembly process

FITTING OF CORE IN THE TANK

The most commonly used method of putting the core assembly is to restthe core frame on its
feet, which in turn is firmly fixed on the tank base. Theextreme end feet are enclosed in a steel
bracket welded on the tank base. The topportion of core assembly is also suitably locked with the
tank cover, so that anypossible magnification of the vibration during transit is fully arrested. An
alternativeto this is construction of the tank base in the shape of a channel. The laminationsalong
with the bottom-end frames are jacket from either side against the channelwalls of the tank. As
such, no bolts are needed in the bottom yokes and ironlossesare comparatively lower.

VOLTAGE REGULATION AND TAPCHANGER

The device tapchanger is used for adding or cutting out turns of primaryor secondary winding of
the transformer. Basically tapchanging equipment can bedivided in two categories.

1. OFF-CIRCUIT TAPCHANGER

Also called No-Load Tap Changer (NLTC) or De-Energized Tap Changer (DETC)
The cheapest method of changing the turn ratio of a transformer is the use of offcircuit
tapchanger. As the name implies, it is essential to de-energize the transformerbefore changing
the tap.
An off-circuit tapchanger, as shown in Fig. 12, consists of principally the followingthree parts:
(a) Operating handle projecting outside the transformer.
(b) Fixed contact with connecting terminal
(c) Insulating shaft with moving contact system.

~ 34 ~
The basic transformer winding circuit arrangements using off-circuittapchanger are:
(a) Linear
(b) Single-bridging
(c) Double-bridging
(d) Series-parallel
(e) Star-delta
Depending upon the requirement, any of the above arrangements of thewinding can be made use
of to get desired voltage regulation. To preventunauthorized operation of an off-circuit
tapchanger, a mechanical lock is provided.
Also to prevent inadvertent operation, an electromagnetic latching device ormicroswitch is
provided to open the circuit breakers to de-energize the transformerwhile operating the handle of
tapchanger before movement of contacts on tapswitch.

Fig.14. Off load tapchanger

2. ON-LOAD TAPCHANGER (OLTC)

On-load tapchangers are employed to change turn ratio of transformer toregulate system voltage
while the transformer is delivering normal load. With theintroduction of on-load tapchanger, the
operating efficiency of electrical systemhas considerably improved. Now-a-days, almost all the
large power transformersare fitted with on-load tapchanger.
All forms of on-load tapchanging circuit posses an impedance, which isintroduced to prevent
short circuiting of tapping section during tapchangeroperation. The impedance can be either a
resistor or centre-tapped reactor. Theon-load tapchanger can in general, be classified as resistor
or reactor type.

~ 35 ~
 COOLING ARRANGEMENTS
In power transformer, the oil serves a dual purpose as an insulating mediumas well as a cooling
medium. The heat generated in the transformer is removedby the transformer oil surrounding the
source and is transmitted either toatmospheric air or water. This transfer of heat is essential to
control the temperaturewithin permissible limits for the class of insulation, thereby ensuring
longer lifedue to less thermal degradation.

1. VARIOUS TYPES OF COOLING

ONAN Type Cooling
In case of smallerratings of transformers, its tank may be able to dissipate the heat directly to
theatmospheric air. Inthese cases, the heat dissipation is from transformer oil to atmospheric air
by naturalmeans. This form of cooling is known as ONAN (oil natural, air natural) type
ofcooling.
ONAF Type Cooling
For further augmenting the rate of dissipation of heat, other means such asfans blowing air on to
the cooling surfaces are employed. The forced air takesaway the heat at a faster rate, thereby
giving better cooling rate than natural air.This type of cooling is called ONAF (oil natural, air
forced) type of cooling. In thiscooling arrangement, additional rating under ONAN condition viz.
after shuttingoff fans, is available, which is of the order of 70-75%.
OFAF Type Cooling
Still better rate of heat dissipation could be obtained if in addition to forcedair, means to force
circulate the oil are also employed. The oil can be forced withinthe closed loop of transformer
tank and the cooling equipment by means of oilpumps. This type of cooling is called OFAF (oil
forced, air forced) type of cooling.
Mixed cooling transformers of radiator type can have two or three ratings available,one for each
type of cooling, viz, OFAF, ONAF and ONAN.
OFWF Cooling
Since the ambient temperature of water is always less than the atmosphericair, it is possible to
use water as a better heat-transfer media. Such an arrangementemploys oil to water heat
exchangers. A prerequisite for such an arrangement isthe availability of a source of sufficient
quantity of water. In most of the transformersfor hydropower stations, this type of cooling is
used. Such a cooling is calledOFWF (oil forced, water forced) type of cooling.
Forced Directed Oil Cooling
Additional means of improving the heat dissipation rate are also employedon higher ratings for
transformer. These comprise arrangements which direct thetransformer oil in the windings
through predetermined paths. This directed oil flowtype of cooling is utilized with advantage in
case of forced oil system. The cool oilentering the transformer tank from the cooler/radiators is
passed through thewindings in a pre-decided manner ensuring faster rate of heat transfer. This
typeof cooling is called ODAF (oil directed, air forced) or ODWF (oil directed, waterforced)
type.

~ 36 ~
 DESIGN PROCEDURE
1. SPECIFICATIONS OF TRANSFORMER- Complete specifications must be furnished for
designing the transformer to suit the specific requirements. In the following paragraphs design
procedure, selection of various parameters and their effect on the various performance criteria
has been discussed.

2. SELECTION OF CORE DIAMETER- Core diameter of a transformer depends upon a

number of factors likerating, percentage impedance between windings, basic insulation level,
transportheight, overfluxing requirements, type of core and quality of core steel. Based on
this, guaranteedparameters, viz percentage impedance and losses are worked out. Core
diameteris adjusted to meet the guaranteed parameters.

 Influence of Varying Core Diameter- Increasing core diameter increases area of cross-
section, thereby increasing voltage per turn, which reduces the number of turns in various
windings. Thepercentage reactance between windings is directly proportional to number of
turnsand diameters of various coils and is also inversely proportional to volts per turnand coil
depth. In order to have specified reactance, increased core diameternecessitates reduction in
coil depth and increase in coil dimensions in lateraldirection, which leads to reduction in core
height and increase in core leg centres.Inspite of reduction in core height due to increase in
core diameter, overall weightof core steel increases, which also increases no-load loss of
transformer. Also,reduced number of turns in windings even with larger length of mean turn
resultsin reduced copper weight, which in turn also reduces the load loss of
transformer.Similarly, reduced core diameter results in reduced core steel weight and no-
loadloss increased copper weight and load loss.

 Core Area- Stepped core construction is used to obtain an optimum core area
withincircumscribing circle of a core. Core area depends upon number of steps, gradeof core
steel, insulation on the laminations, i.e. varnished or unvarnished, andmethod of core
clamping. As the number of steps increases, core area alsoincreases, however it needs extra
labour to cut the various sizes of laminations.Optimum numbers of steps are used to give
overall economy. Large ratingtransformers are usually provided with high tensile steel clamp
plates for clampingthe core laminations, which provide increased core area for a particular
core diameter. Depending upon the flux density in the core, adequate numbers of ducts are
provided to keep its hot-spot temperature and cooling ducts in core.

3. SELECTION OF FLUX DENSITY-Normallyflux density is chosen near knee point of

magnetization curve, however, adequate margin should be kept to take care for system
conditions like overfluxing, frequency and voltage variations. In certain cases value of flux
density is reduced to limit thenoise level of transformers.

 Influence of Varying Flux Density-Keeping the other parameters same, increase in the
value of flux density inthe core result in higher volts per turn. Hence numbers of turns in
various windingsare reduced. Effect of increase of flux density on reactance is similar to
that ofincrease in core diameter. In order to meet the requirement of specified

~ 37 ~
 reactance,coil depth is reduced and lateral dimensions of coils are increased. Inspite
ofsmall increase in core leg centres, reduced core height results in lower core-steelweight
results in higher no-load loss of transformer. Also reduced number of turnsin windings
results in lower copper weight and load losses. Similarly, reduction inthe value of flux
density causes increased core-steel weight, lower no-load lossand increased copper
weight and load loss.

4. loadedconditions, on-load tapchangers are provided. Generally, unit auxiliary

transformers,station transformers, and system transformers are provided with on-
loadtapchangers. The choice of tapchangers is governed by the following factors:
 Tapping range
 number of steps
 Step voltage
 Current rating
 Location of tapping
 Design of tapping winding, i.e. linear, reversing, coarse and fine.
 Insulation level
 Type of voltage variation, i.e. constant flux, variable flux and mixed type.
 Power flow requirement, i.e. unidirectional or bi-directional

5. CALCULATION OF NUMBER OF TURNS- It is done by using emf equation:

Volts per turn, Et=4.44BmAƒ
where Bm=Maximum flux density in tesla
A=net cross-sectional area of core in m2.
ƒ= frequency in Hertz

6. SELECTION OF CURRENT AND CURRENT DENSITY

7. INSULATION DESIGN
8. CALCULATION OF LATERAL AND AXIAL DIMENSIONS OF COIL
9. AMPERE TURN BALANCING
10. REACTANCE CALCULATION
11. IRON WEIGHT AND LOSSSES
12. COPPER WEIGHT AND LOSSES
13. STRAY LOSSES IN TRANSFORMER
14. IMPULSE CALCULATION
15. MECHANICAL FORCESIN WINDINGS
16. TEMPERATURE GRADIENT AND COOLING CALCULATION

~ 38 ~
 TRANSFORMER AUXILIARIES AND OIL PRESERVATION
SYSTEMS
Transformer auxiliaries play a vital role in ensuring proper functioning of themain equipment.
Some of the auxiliaries provide protection under fault conditions.
Transformer oil being a major insulation requires special attention againstcontamination by
moisture and oxygen for preservation of quality.

TRANSFORMER AUXILIARIES
1. GAS OPERATED (BUCHHOLZ) RELAY
The relay serves as main protection for any minor or major faults that maydevelop inside a
transformer. Such faults always result in generation of gaseswhich causes the operation of
mercury switches giving signal for audible alarm orisolates the transformer from the network. It
comprises a casthousing which contains two pivoted buckets, each bucket being counter-
balancedby a weight. Each assembly carries a mercury switch, the leads from which aretaken to
a moulded terminal block.
Operation- The relay is mounted in the pipe atan inclination of 3-7º as shown in Fig. 1 Inhealthy
condition of the transformer, therelay is full of oil and both the mercuryswitches are open. In the
event of a minorfault like damage to core bolt insulation,local overheating, etc. the arcing
causesslow generation of gas in the oil, whichpasses up in the pipe and gets trapped inthe relay
housing. As the gas accumulates,the oil level in the relay falls, leaving thetop bucket full of
oil.When a sufficient volume of gas is collected in the relay, the top bucket,because of its extra
weight due to oil contained, tilts, overcoming the balanceweight which closes the mercury switch
and initiates an audible alarm.
With a major fault like short-circuit between turns, coils or between phases;the generation of
gases is rapid and the gas and the displaced oil surges throughthe relay and impinges on the
baffle plates, causing the lower assembly to tilt andclose the mercury switch and provide signal
for tripping the circuit breaker, whichdisconnects the transformer from the network.

2. TEMPERATURE INDICATORS
Temperature indicators are precision instruments, specially designed forprotection of
transformers and perform the following functions.
 Indicate maximum oil temperature and maximum or hottest spottemperature of winding.
 Operate an alarm or a trip circuit at a predetermined temperature.
 Switch on the cooling equipment when the winding attains a preset hightemperature and
switch it off when the temperature drops by an establisheddifferential (so as to avoid too
frequent on and off operation of the switch).

Normally two separate instruments are used for indicating oil and windingtemperatures.

3. PRESSURE RELIEF VALVE

The pressure relief valve plays a significant role in the protection of powertransformer
systems.As mentioned before, a major fault inside the transformercauses instantaneous
vaporization of the oil, leading to extremely rapid build-upof gaseous pressure. If this pressure is
not relieved within a few milliseconds, thetransformer tank can get ruptured, spilling oil over a

~ 39 ~
wide area. The consequentdamage and fire hazard possibilities are obvious. A pressure relief
device providesinstantaneous relieving of dangerous pressure.

4. OIL LEVEL INDICATOR

Normally all transformers are provided with an expansion vessel calledconservator, to take care
of expansion in the oil volume due to rise in temperature,when the load on the transformer
increases or due to increase in ambienttemperature. The oil level in the conservator consequently
goes up. Conversely, itfalls when the temperature or load reduces. It is essential that the oil level
in theconservator is maintained above a pre-determined minimum level. All largetransformers
are, therefore, fitted with a magnetic oil level gauge which alsoincorporates a mercury switch.
The switch closes and actuates an audible alarmin the event of oil level dropping to near empty
position in the conservator.

5. BUSHING AND CABLE SEALING BOX

It is necessary to bring the low and high voltage leads out of transformer tank, tobe able to make
connections between transformer and generator or transmissionlines, etc. This is accomplished
by terminating these leads through what are knownas bushings or cable box.
A bushing is a structure carrying a conductor through a partition in the tankand insulating the
conductor form partition.

Cable Sealing Box

Generally used for termination of leads of low voltage, a cable sealing boxis designed for the
purpose of receiving and protecting the end of a metal-sheathedcable or cables and containing a
suitable insulating medium.
It is a unit complete with bushings, to which the terminals of the transformer canbe connected.
The insulating medium in a cable box can be air or a bituminouscompound.

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6. TRANSFORMER OIL PRESERVATION SYSTEMS
Transformer oil deterioration takes place due to moisture. Moisture canappear in a transformer
from three sources, viz. by leakage past gasket, byabsorption from air in contact with the surface,
or by its formation within thetransformer as a product of deterioration as insulation ages at high
temperature.
The effect of moisture in oil is to reduce the electric strength, especially if loosefibres or duct
particles are present.
Methods available to reduce oil contamination from moisture are silicagel breather,
thermosyphon filter, sealed conservator tanks using gas cushion, rubberdiaphragm or air-cell
sealed refrigerated dryers.

Silicagel Breather
A silicagel breather is most commonly employed as a means of preventingmoisture ingress. It is
connected to the conservator tank, which is fitted totransformer to allow for changes in volume
due to temperature variations. As theload reduces, air is drawn into the conservator through a
cartridge packed withsilicagel desiccant, which effectively dries the air. Freshly regenerated gel
is veryefficient, it will dry the air down to a dew point of below- 40 ºC, but quickly falls
inefficiency. A well maintained silicagel breather will generally operate with a dewpoint of -
35ºC, as long as a large enough quantity of gel has been used for thecycling duty.
Silicagel may be reactivated by heating in a shallow pan at a temperatureof 150º to 200ºC for
two to three hours when the crystal should have regainedtheir blue tint.

17. RADIATORS AND FANS- They are used for cooling of the oil.

MANUFACTURING AND ASSEMBLY

Manufacturing and assembly of the transformer involves the following mainstages and the
manufacturing techniques basically depend on the design philosophy.
(a) Core building
(b) Preparation of windings
(c) Core and winding assembly
(d) Terminal gear assembly
(e) Placement of care and winding assembly in tanks.
(f) Processing
(g) Servicing and tanking

Core building
The base is made up of frames on which core is mounted as shown in figure. The top and
end frame and bottom end frame are connected.

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 Fig. core Layout

Core building done on three 65T cradle, which ensures minimum jerk during lifting of core.
Construction in which the iron circuit is surrounded by windings and forms a low reluctance path
for the magnetic flux set up by the voltages impressed on the primary.

The steel strip surface is subjected to inorganic insulation treatment. All cores employ meter-
joint core construction. Yokes are jointed at an angle of 45° to utilize the magnetic flux
directional characteristic of steel strip.

When erecting a core after assembling, a special device is used so that no strain due to bending
or slip is produced on the silicon steel.

The sequence of operations for core building and assembly are as under:
(a) Slitting of core steel rolls to required width on slitting machines.
(b) Cropping and mitring to the required dimensions.
(c) Hole punching in the laminations where required.
(d) Stacking of laminations of different size to the required thickness.
(e)Laying of clamp plates and end frame and its levelling.
(f) Assembly of insulation between clamp plate/end frame & core laminations.
(g) Preparation of oil duct in core.
(h) Core building.
(i) Clamping of core after assembly of the top end frame.
(j) Tightening of core.

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(k) Lifting of core by use of a cradle, and carrying out isolation checksafter treatment of
insulation items.
The core assembly is now ready for further processing and assembly.

Preparation of windings
The sequence of manufacture of windings is given below:
(a) Loading of moulds (formers) on the windings machines.
(b) Loading of the conductor reels on stands.
(c) Dressing of the mould, i.e. assembly of insulation spacers and blocks onthe mould.
(d) Manufacture of the winding on horizontal/vertical winding machines dependingon design,
type of winding, number of conductors, to be handled at atime and the type of conductor.
(e) Preparation of the leads etc.
(f) Dismantling of winding from the machine.
(g) Preparation of the joints between conductors, if any.
(h) After removing the winding from the winding machine, each winding isclamped between top
and bottom plates through tie rods, and kept in anoven for heating. The windings are
individually shrunk to the required axialdimensions by heating in the steam heated oven and
by applying the requiredpressure. Heating ensures removal of moisture from the
insulationitems. This process is called stabilization of the windings, and the windingsare
stabilized to such an extent that they do not shrink further during service.

Core and winding assembly

Core is placed on suitable levelled platform. Top-end frame and yoke laminationsare removed.
This process is known as unlacing of core. Bottom insulation items are placed on bottom
yoke/endframe on each core leg. Various windings are either lowered one by one or
compositewinding assembly is lowered on each core leg. After lowering of the windings,top
insulation arrangement is completed. Top-end frame and yoke laminationsare placed back in
position. This is known as relacing of core. Coils are kept under pressure by either coilclamping
bolts or spring loaded hydraulic devices provided on the top-end frame.

Terminal gear assembly

After relacing of the top yoke, the preparation of the Terminal Gear Assemblydone as described
below:
(a) Cutting of the leads as required.
(b) Crimping/brazing of the leads with cables.
(c) Brazing of bus bars.
(d) Fixing of different cleats.
(e) Crimping/brazing of cables with terminal lugs.
(f) Mounting of the tap changer/tap switch.
(g) Preparation of HV line lead.

The connections available in this stage are either of the following two types or a combination of
these two types:

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 a. Star Connection: Also called Wyes winding. Each phase terminal connects to one end of
a winding and other end of a winding connects to other at a central point, so that the
configuration resembles a capital letter Y. The central point may or may not be connected
outside of the transformer.

b. Delta Connection: Also called mesh winding. In delta connection the bottom position
lead of one coil is joined to the top or starting position lead of the second coil and the
bottom lead of second coil are joined to top lead of the third coil and the top lead of the
first coil is connected to bottom lead of third coil. In H.V. side the H.V. main lead is
taken out and the various tap leads are then joined to OLTC (On Load Tap Changer)
through conductors. The conductors to the tap changer can be observed in the H.V.
marked as (3-14) in numbers these are then connected to the tap changer. All the leads
are properly brazed for accurate connections so that same amount of current flows
through each conductor and the ratio can be achieved. In L.V. side the bottom leads of
the L.V. coils are joined together to form neutral. Whereas the top lead positions are
taken out for respective 3-Ø connection.

Placement of core and winding assembly in tank

After completion of terminal gear assembly, the core and winding assemblyis placed in the tank.
The tank may either be of conventional or bell-shapedconstruction depending upon requirement.
In case of bell-shaped constructionthe top part of tank and for conventional construction the
bottom tank is preparedfor this purpose. Preparations include mounting of shunts, barriers, etc.,
on tankwalls as required and also laying of gaskets on the flange joints. In conventionaltank, the
core and winding assembly is lowered on the core and winding assembly.
In bell-shaped tank construction, top tank is lowered on the core and windingassembly.
After placement of core and winding assembly in tank, various electricaland mechanical
clearances, viz. coils to tank, line, neutral and tapping leads totank, etc., are checked. After the
above checks are over, all the openings in tankand cover are blanked by blanking plates and
gaskets. The transformer is thensent for drying and impregnation.

Processing
The quality of a transformer and, consequently its performance and lifedepends essentially on the
factory processing. The assembled active part of thetransformer after tanking or before tanking
as the case may be, is heated in anoven for extraction of moisture under vacuum. Sometimes,
vacuum drying is doneby drawing vacuum in its own tank and keeping the whole transformer in
an oven.
Besides the conventional method of drying, the most modern vapour properdry out, as otherwise
windings would become loose in service, and may get distortedunder short circuit conditions.The
paper insulation and pressboard material, which make up a significant proportion by volume of
transformer windings, have the capacity to absorb large amounts of moisture from the
atmosphere. The presence of this moisture brings about a reduction in the di-electric strength of
the material and also an increase in its volume.
The fimal drying out is commenced either when the core and windings are placed or when they
are fitted into tank, all main connections made, and the tank placed in an oven and connected to
the drying system. The tapping switch may be fitted at this stage, or later, depending on the
ability of the switch components to withstand the drying process.

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Once the moisture is extracted to the desired level, oil is filled under vacuumand the transformer
is soaked in oil.

CONCLUSION
The power transformer is the most important component of the power transmission
and distribution . A transformer works on the principles of induction which states
that only the current and voltages shall be transformed and energy will only get
‘transferred’.

BHEL is a leading Engineering Enterprise which Supplies wide Spectrum of

Power Transformers. These transformers undergo several stages of manufacturing
process and at the end of every process various tests like type tests, routine tests
etc. are performed on them to ensure its status during manufacture and a reliable
operation after manufacturing.

These four weeks helped me a lot in gaining the knowledge on power transformers.
It made me aware of various stages of transformer manufacturing processes and
different tests that are conducted on them.

This report clearly replicates the tremendous growth of a company which

continuously renovated its technology to contribute not only in the infrastructure
building in India but also of the world.

It is an asset for our country to have such a public sctor industry which has fulfilled
the dream of our first Prime Minister Sh. Jawaharlal Nehru by operating in 65
countries and making it to global.

The vision and mission of this company are successful can be adjudged with the
faith of the stake holders in this company.

BHEL Jhansi although a smaller unit in comparision to otherunits of BHEL, is a

very productive one with the manufacturing of the electric locomotives, power
transformers etc.

The work load here can be accessed from the fact that the order of the locomotives
has forced the company to shift its Bus Duct section to other unit of BHEL.

In future also the company is having orders of metro coaches and this clearly
shows why this company is still recession proof.

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