TRANSFORMER DESIGN

DESIGN, ENGINEERING, SELECTION,

MANUFACURING, ASSEMBLY OF TRANSFORMERS
 PURPOSE OF SELECTION
1. Optimized Selection of Transformer which fits the purpose
2. Reliable and Sustainable
3. Safety to working professionals during operations and
maintenance.
4. Minimum failure rate
 IMPORTANT CODES AND
STANDARDS
1. CBIP Manual on Transformers.
2. IS 11171 - Dry Type Transformers
3. IS 1180 - Energy Efficient Transformer upto 2.5 MVA
4. IS 2026 - Power Transformers
5. IEC 60076 - Power Transformers
 MAIN TYPES OF
TRANSFORMER
OIL TYPE & DRY TYPE
Selection of Dry type vs Oil Type Transformer
 TRANSFORMER DESIGN
TRANSFORMER TANK

• Transformer tanks are made of robust mild steel plates with low carbon content
• Transformer tank plate thickness shall be suitable to meet the overpressure and vacuum tests mentioned in CBIP manual.
• Tanks shall be suitable to meet the earthquake forces as per the installed Siesmic zone.
• Tank design and construction shall ensure that no internal pockets for air/gas accumulation can be formed.
• Tanks shall be mounted on bi-directional rollers with locking arrangements.
• Tank shall have bolted inspection covers for inspection.
• The bolter connections shall have weather proof hot resistant gaskets to ensure oil tightness.
• Tanks shall have manhole to enable inspection of core and winding.
• All fastners shall be hot dip galvanized with zinc passivation.
• Provision of drain valves shall be provided to drain out the entire oil from the transformer tank when required.
• Earthing provisions shall be provided preferably on the diagonnaly opposite sides of the tank for external earthing connections.
 TRANSFORMER DESIGN
TRANSFORMER CORE

• Transformer core shall be constructed from high quality non-ageing, cold rolled grain oriented (CRGO) , electrical grade silicon
sheets coated with heat and oil resistant insulation.
• Both sides of the cores shall be properly laminated.
• The core material shall be BIS grade, preferably M4 or better.
• The core shall be boltless in design.
• The insulation structure for core to core bolts & core to the clamping plates shall undergo DC H.V test of 2 k.V rms for 1 min.
• Steel sections for supporting the core shall be sand blasted post cutting, drilling and finally welding.
• The maximum flux density at any part of core and yoke at rated voltage and frequency shall be so that with +12.5% combined
voltage and frequency variation shall not exceed 1.9 Tesla as specifed in IS 2026.
• Lifting lugs shall be provided in the core for lifting purposes.
 TRANSFORMER DESIGN
TRANSFORMER WINDING

• Transformer windings shall be made of electrolytic grade copper (EC grade).

• The windings shall be manufactured in a controlled enviornment free from dusts.
• Preferably the class of insulation shall be “Class-A” for oil filled transformer and “Class F or Class H for dry type transformer.
• Windings shall be brought out and terminated on outdoor bushings, cable boxes or bus-duct chamber, which will be located as
specified on the data sheet.
• For transformers having provisions for terminating TPN bus duct on the 433V side, neutral of the star connected secondary
winding shall be brought out to a secondary terminal chamber
 TRANSFORMER DESIGN
TRANSFORMER OIL

• Transformer oil shall be supplied with with Oil as per IEC 335 or IEC 600296, Type 1 mineral insulating oil.
• The transformer oil shall be certified to non conformance of non-polychlorinated biphenyls (PCB’s).
• The transformer oil shall be also be tested for oil breakdown voltage.
 TRANSFORMER DESIGN
TRANSFORMER RADIATOR

• Oil type transformer shall have detachable radiators.

• Radiators shall be provided with isolating valves.
• Each radiator section shall be provided with detachable type lifting lugs with air release valve, drain valve.
• The radiators shall be rated to withstand the overpressure conditions specified for the transformer tank.
• Shut off valve shall be provided at each point of connection to the transformer tank.
 TRANSFORMER DESIGN
MAIN TANK CONSERVATOR

• Conservator shall be designed to meet the expansion and contraction in the transformer oil volumes respectively.
• Conservations shall have air cells for oil preservation system.
• Conservator shall also have drain valve with blanking plate and oil filling hole cap.
• One prismatic oil level gauge shall be provided.
• In case of Ol line tap changer (OLTC) additional MOG shall be provided in the OLTC.
• Silica gel breather shall be p rovided at accessible location from the ground. They shall be preferably orange coloured which
are enviornment friendly and non-toxic type.
 TRANSFORMER DESIGN
TRANSFORMER MARSHALLING BOX

• Marshalling box shall be made of CRCA sheet steel.

• All transformer internal cablings shall be terminated in the terminal box for external connections.
• Marshalling box shall have mechanical gauge for OTI and WTI.
• Required alarm and trip contacts shall be wired to the terminal block of the marshalling box.
 TRANSFORMER DESIGN
PRE ORDER STAGE DOCUMENTS

• RFQ , followed by TQ and TBE for Transformers

 TRANSFORMER DESIGN
POST ORDER STAGE DOCUMENTS

• All required Vendor documents/drawigs which are agreed in pre-order stage shall be reviewed, commented and finally approved
in post order stage before manufacturing clearances.
TRANSFORMER DESIGN
INSPECTION AND TEST PLAN WITH QUALITY
REQIREMENTS
• All standard ITP shall be agreed with the Vendor as part of RFQ stage which shall list the stage wise
inspection and test requirements which needs to be carried out for the transformers. The tests are
already specified in the IS/IEC/CBIP standards. The same shall include FAT and SAT.
TRANSFORMER DESIGN

TRANSFORMER SIZING CALCULATION

• Objective:
1. To calculate the transformer capacitiy based on the load requirments and also carry out voltage
regulaation check on transformer secondary terminals within tolerable limits.
2. The recheck on the selected transformer rating as mentioned in point 1 with regards to the largest
motor starting when other base loads are in running conditions.
TRANSFORMER DESIGN

TRANSFORMER SIZING CALCULATION

• Basis of Design/Inputs:
1. The Load list or load profile which shall be connected to the transformer along with voltage
regulation check while starting the largest motor when the base load in in running condition.
2. X/R ration of the transformer as per the applicable codes and standards.
3. Impedance of the transformer as per applicable codes and standards.
TRANSFORMER DESIGN

TRANSFORMER SIZING CALCULATION

• Assumptions:
1. Transformer spare capacity of 20% for Oil type transformer and 10% as per dry type transformer shall
be considered while the maximum consumed load is considered in the transformer sizing calculation.
2. Future expansion requirements needs to be clarified during the transformer sizing calculation based
on the Customer requirements.
TRANSFORMER DESIGN

TRANSFORMER SIZING CALCULATION

• Codes and Standards:

1. IS 2026
2. IEC 60076
TRANSFORMER DESIGN
TRANSFORMER SIZING CALCULATION
• Transformer Sizing Calculation:
TRANSFORMER DESIGN
TRANSFORMER SIZING CALCULATION
• Transformer Sizing Calculation:
 TRANSFORMER DESIGN
QUESTIONS AND ANSWER SESSIONS

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