MILLENNIUM INSTITUTE OF

TECHNOLOGY
& SCIENCE
DEPARTMENT OF ELECTRICAL ENGINEERING

INDUSTRIAL TRAINING REPORT

ON

TRANSFORMER & SCR

AT

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Submitted in the partial fulfilment for the degree of
Bachelor of Engineering
SESSION (2009-13)

UNDER THE GUIDANCE OF: BY:Mr . SHYAM LAL

SUBMITTED
SONAM SINGH

MANAGER
ELECTRICAL&ELECTRONICS
(EMX DEPARTMENT)

0179EX091049

CERTIFICATE
TO WHOM IT MAY CONCERN
This is to certify that Ms. SONAM SINGH student of B.E in
Electrical&Electronics Engineering, Roll. No. 0179EX091049 from
Millennium Institute of Technology & Science, Bhopal M.P has undergone 6
week industrial training in BHEL, BHOPAL under the guidance of Mr.
SHYAM LAL Manager at EMX DEPARTMENT , Bharat Heavy Electricals
Limited (BHEL),Bhopal from JUNE 11, 2012 to JULY 21, 2012 & her training
work entitled TRANSFORMER & SCR submitted in the department of
HRDC is a bonafide work carried out during this period. It is further certified
that the work reported in the project fulfils the requirement of the ordinance
related to the degree of B.E. in Electrical& Electronics Engineering from
MITS, Bhopal. Her discipline and performance during the training period was
excellent. We wish him a very prosperous and bright career in future.

Mr.SHYAM LAL
MANAGER , EXM Dept.
BHEL, Bhopal

ACKNOWLEDGEMENT
Presenting the Training report today remains an unparalleled event for us as
it recapitulates all our toils and effort to every one who made it possible for
us to achieve something.

Wherever and whatever we present today has been made possible by the
undying efforts of Training Guide MR. SHYAM LAL (MANAGER, EXM).
He always made available whatever we needed lab time, extended lab hours
and most important his guidance.

Last but not least, we wish thanks all those noble hearts who directly or
indirectly helped us to complete this training.

DECLARATION
I hereby declare that work which is being presented in the training
entitled on TRANSFORMER & SCR is the partial fulfillment for
the award for degree for bachelor of engineering in Electrical &
Electronics Engineering. The work has been carried out at BHEL,
Bhopal and is the authentic record of my own work.

I hereby declare that the above statement is true to the best of my

knowledge.

Date: 21-07-12
Token no. VT /659/12

Contents
1. Introduction to Organisation
2. Introduction to Transformers
3. Transformers construction
4. Testing of transformers
5. Introduction to Rectifiers

1.1 Introduction to BHEL

In the post independence era when India was moving towards
industrialization, the thrust by the government was in the core sector. With
this 1956, with a view to reach self sufficiency in industrial products and
power equipments. This plan was setup under collaboration of M/s.AEJ,
U.K. .
Now more plants were setup at Trichy, Hyderabad and Haridwar with
Czechoslovakian and Soviet Union assistance in May 1956, Dec. 1956 and
Jan 1957 respectively. Today B.H.E.L. has become the largest engineering
plant employing approximately 72000 employees. Its headquarters are
located at Delhi. B.H.E.L. is the largest engineering and manufacturing
enterprise in India in the energy/infrastructure sector today. B.H.E.L. was
established more than forty years ago ushering in the indigenous heavy
electrical equipments industry in India dream that has become more than
realized with a well-recognized track record of performance. It has been
earning profits since 1971-72 and paying dividends since 1976-1977.
B.H.E.L. manufactures over 180 products under thirty major product groups
and caters to core sectors of the Indian Economy viz., Power Generation
and Transmission, Industry, Transportation, Telecommunication,
Renewable Energy, etc. The wide network of B.H.E.L.s fourteen
manufacturing divisions, four power sector regional centres, over hundred
project sites, eight service centres and eighteen regional offices, enables the
company to prompt severe its customers and provide the with suitable
products efficiently and at competitive prices.

The quality and reliability of its products is due to the emphasis on design,
engineering and manufacturing to international standards by acquiring and
adapting some of the best technologies from leading companies in the world,
together with technologies developed in its own R&D centres.
B.H.E.L. has acquired certificates to Quality Management Systems- ISO 9001,
Environmental Management Systems- ISO 14001 and Occupational Health and
Safety Management Systems- OHSAS 18001 and has also adopted the concepts of
Total Quality Management.
B.H.E.L. has installed equipment for over 90,000 MW of power generation- for
Utilities, Captive, and Industrial users. It supplied over 2,25,000 MVA
transformer capacity and sustained equipment operating in transmission and
distribution network up to 400 KV- AC & DC.
It supplied over 25,000 motors with Drive Control System to power projects,
petrochemicals, refineries, steel, aluminium, fertilizer, cement plants, etc. It also
supplied traction electrics and AC/DC locos to power over 12,000 km railway
network. It supplied over one million valves to power plants and other industries.
B.H.E.L.s vision is to become a world class engineering enterprise, committed to
enhance stakeholder value. The company is striving to give shape to its
aspirations and fulfil the expectations as a Navratna Company.
The greatest strength of B.H.E.L. is its highly skilled and committed 44,000
employees. Every employee is given an equal opportunity to develop himself and
improve his position. Continuous straining and retaining career planning, a

positive work culture and participative style of management have endangered

development o a committed and motivated work force leading to enhanced
productivity and higher levels of a quality.
PRODUCT PROFILE:
With an export presence in more than 60 countries, BHEL is truly Indias
industrial ambassador to the world. This list is intended as a general guide
and does not represent all of BHEL's products and systems.

Thermal Power Plants

Steam turbines and generators of up to 500MW capacity for utility and
combined-cycle applications; capability to manufacture steam turbines with
super critical steam cycle parameters and matching generator up to 1000
MW unit size.
Gas based Power Plants
Gas turbines of up to 260MW (ISO) rating.
Gas turbine based co-generation and combined-cycle systems for industry
and utility applications.
Hydro Power Plants
Custom-built conventional hydro turbines of Kaplan, Francis and Pelton
types with matching generators, pump turbines with matching motorgenerators. Mini/micro hydro sets.
Spherical, butterfly and rotary valves and auxiliaries for hydro station DG
Power Plants
HSD, LDO, FO, LSHS, natural-gas/biogas based diesel power plants, unit
rating up to 20MW and voltage up to 11kV, for emergency, peaking as well
as base load operations on turnkey basis.
Industrial Sets
Industrial turbo-sets of ratings from 1.5 to 120MW.

 Gas turbines land matching generators ranging from 3 to 260MW (ISO)

rating.
Industrial stream turbines and gas turbines for drive applications and cogeneration applications.

Boilers and Auxiliaries

Steam generators for utilities, ranging from 30 to 500MW capacity, using
coal, lignite, oil, natural gas or a combination of these fuels: capability to
manufacture boilers with super critical parameters up to 1000 MW unit size.
Steam generators for industrial applications, ranging from 40 to 450t/hour
capacity using coal, natural gas, industrial gases, biomass, lignite, oil,
biogases or a combination of these fuels.
Pulverized fuel fired boilers.
Stoker boilers.
Pressure vessels.
Heat Exchangers and Pressure Vessels
Air-cooled heat exchangers.
Surface condensers.
Steam jet air ejectors.
LPG/propane storage bullets.
Feed water heaters.
Power Station Control Equipment
Microprocessor-based distributed digital control systems.
Sub-station controls with SCADA.
Static excitation equipment/automatic voltage regulator.

 Electro-hydraulic governor control.

Turbine supervisory system and control.
Controls for electrostatic precipitators.
Controls for HP/LP bypass valves.

Switchgears
Switchgear of the various types for indoor and outdoor applications and
voltage ratings up to
400 kV.
Minimum oil circuit breakers (66K 132kV).
SF6 circuit breakers (132 kV 400 kV).
Vacuum circuit breakers (3.3 kV 33 kV).
Gas insulated switchgears (36 kV).

Transformers
Power transformers for voltage up to 400 kV.
HVDC transformers and reactors up to + 500 kV rating.
Series and shunt reactors of up to 400 kV rating.
Current transformers up to 400 kV.
Electro-magnetic voltage transformers up to 220 kV.
Capacitor voltage transformers up to 400 kV.
Special transformers: earthing; furnace; rectifier; electrostatic
precipitator; freight loco and AC EMU and traction transformers.

Insulators
Disc/suspension insulators for AC/DC applications, ranging from 45 to
400 KN electro- mechanical strength, for clean and pollute atmospheres.
Pin insulators of up to 33 kV.

BHELs ROLE IN POWER SECTOR:

Total installed capacity in India is 1, 34,718 MW, in this BHEL contribution
is around 65%.

In Generation BHEL contribution is around 65%.

17th Electric Power Survey Committee (DRAFT):

o Required installed capacity for the end of XI Plan (2012) is 200 GW

as the demand for power is expected to rise to 157 GW.
o For the end of XII Plan is capacity required is 275 GW.
o Per Capita availability to be increased to over 1000 units by 2012
from existing 600 units.
o Available for all Houses in India.

Introduction to Transformers
DEFINITION:
A transformer is a device with two or more stationary electrical circuits that
are conductively disjointed but magnetically coupled time varying magnetic
field and is used for transferring power one circuit to another by means of
electromagnetic induction at the same frequency. A transformer consists of
the following circuits.
NECESSITY:
Electrical energy generated at generating stations is transported to remote
load centres. Between generating station and consumers we have
transmission, sub transmission and distribution levels of voltage. Since the
long distance transmission at high voltage is cheap and low voltages are
required for utility purpose, the voltage levels goes on decreasing from the
transmission system to the distribution system. For this high voltages and
low voltages transformer is necessary in transmission and distribution
system.
A transformer consists of the following circuits
Magnetic circuit
Comprising limbs (cores), yokes and clamping structures. This offers low
reluctance path for magnetic flux.
Electrical circuit
Comprises of the primary, secondary and territory windings. The primary is
the winding, which receives electric power and secondary, which may
deliver it. These coils are wound on laminated core of magnetic material.

 Dielectric circuit
Consisting of insulation in different forms and used at different places in the

transformer (i.e. core to LV, LV to HV etc.).

Working principle:
The physical basis of a transformer is mutual inductance between two
circuits linked by common magnetic flux through a path of low reluctance. A
transformer can rise or lower the voltage with a corresponding decrease or
increase in current. In its simplest form, a transformer consists of two
conducting coils having a mutual inductance. The primary is the winding,
which receives electric power, and the secondary is the one which may
deliver it. The coils are wound on a laminated core of magnetic material.
The two coils possess high mutual inductance. If one coil is connected to a
source of alternating voltage, an alternating flux is set upon the laminated
core, most of which is linked up with the other coil in which it produces
mutually induced emf (electromotive force) according the Faradays laws
electromagnetic induction, i.e.

e =M di/dt
Where, e =induced emf M = mutual inductance If the second circuit is
closed, a current flows in it and so electric energy is transferred from the
first coil to the second coil.
The transformer is based on two principles: first, that an electric
current can produce a magnetic field (electromagnetism) and second that a
changing magnetic field within a coil of wire induces a voltage across the
ends of the coil (electromagnetic induction). Changing the current in the
primary coil changes the magnetic flux that is developed. The changing
magnetic flux induces a voltage in the secondary coil.

An ideal transformer is shown in the adjacent figure. Current passing

through the primary coil creates a magnetic field. The primary and
secondary coils are wrapped around a core of very high magnetic
permeability, such as iron, so that most of the magnetic flux passes through
both the primary and secondary coils. If a load is connected to the
secondary winding, the load current and voltage will be in the directions
indicated, given the primary current and voltage in the directions indicated
(each will be alternating in practice).

Induction law
The voltage induced across the secondary coil may be calculated from
Faraday's law of induction, which states that:

Where Vs is the instantaneous voltage, Ns is the number of turns in the

secondary coil and is the magnetic flux through one turn of the coil. If the
turns of the coil are oriented perpendicularly to the magnetic field lines, the
flux is the product of the magnetic flux density B and the area A through
which it cuts. The area is constant, being equal to the cross-sectional area of
the transformer core, whereas the magnetic field varies with time according
to the excitation of the primary. Since the same magnetic flux passes through
both the primary and secondary coils in an ideal transformer, the
instantaneous voltage across the primary winding equals

Taking the ratio of the two equations for Vs and Vp gives the basic equation
for stepping up or stepping down the voltage

Np/Ns is known as the turns ratio, and is the primary functional

characteristic of any transformer. In the case of step-up transformers, this
may sometimes be stated as the reciprocal, Ns/Np. Turns ratio is commonly
expressed as an irreducible fraction or ratio: for example, a transformer
with primary and secondary windings of, respectively, 100 and 150 turns is
said to have a turns ratio of 2:3 rather than 0.667 or 100:150.
GENERAL CLASSIFICATIONS:
1. Power Transformers:

These are large transformers generally used to step up voltage at generating

stations and to step down voltage at substations for supply of power to
distribution systems. A transformer rated over 1600 KVA is generally termed
as power transformer.
2. Distribution Transformer:
These are used to lower voltage to a suitable level (440 volts) for use in
street distribution cables, factories and domestic distribution.
3. Special transformer:
Instrument transformer
Furnace transformer
Rectifier transformer
Welding transformer
Booster transformer etc.
These are further classified as
1. Oil filled transformers: these are the one in which windings and core
immersed in insulating oil.
2. Dry type transformers: in dry type transformers they are not placed in
oil.

CORE BUILDING
Core Materials:

CRGO: Cold Rolled Grain Oriented Silicon Steel CRGO electrical steel
sheet with approximate silicon content of 3% is used for magnetic circuit of
a transformer. The following features influence selection of type of steel
sheet
1. Maximum magnetic induction to obtain high induction amplitude in
an alternating field.
2. Minimum specific core loss for no load loss.
3. Low apparent power input for low no load current.
4. Low magnetostriction for low noise level.
5. High-grade surface insulation.
6. Good mechanical processing properties.
The chemical composition of CRGO:
1. Carbon
2. Manganese
3. Phosphorous
4. Sulphur
5. Silicon
6. Steel

Properties of CRGO Steel Laminations

The following features or properties influence for selecting the CRGO steel
sheet as magnetic core circuits for transformers.

Maximum magnetic induction to obtain high induction amplitude in

an alternating field

Core loss will be independent of the load of the transformer. By using

CRGO steel sheets core loss is low result in reduction of the constant
losses.

Low apparent power input (Low hysteresis loss) results in low no load
current

High grade surface insulation

Good mechanical processing properties

Low magnetostriction results in low noise level

In order to appreciate the CRGO Steel material first we have to understand

the core losses in the Transformer.
CONSTUCTIONAL 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. For single phase and three phase transformers, the cores can be
broadly classified as
1. Single phase three limbed core.
2. Single phase two limbed core.

3. Three phase three limbed cored.

4. Three phase five limbed core
For building the transformer cores, lamination sheets of different widths
and packet heights are needed. Laminations are produced by the
following operations.
1. Core slitting:
The manufacturing schedule may include cores of different diameters
and different types of constructions necessitating slitting laminations in
many widths and lengths. CRGOS rolls cannot be ordered in so many
different widths and quantities. These rolls are available in standard
widths of 790, 840, 1000 etc. For slitting operation, some widths can be
combined together by suitably adjusting the cutter distances in the
slitting machine. It is evident that full width of roll cannot be utilized at
any time of slitting operation and the leftover material will vary from
stage to stage and depending on the widths selected in combination
during the process of slitting. The meticulous care in planning is
imperative to minimize wastage of core steel.
2. Core cutting:
Different shapes and sizes of laminations are needed for different types of
transformer cores. Hence, in this operation a cropping machine is for
cutting laminations from slotted rolls. Depending upon the shape of
cutting these laminations are grouped into following sets.
1. ABCD

2. PQR
3. PQRS
3. Piercing:
The yoke punching (laminations) usually need holes for bolting the yoke
laminations. These holes are punched after the cropping operation by
suitably adjusting the hole piercing positions in the piercing machine and
selecting the right piercing tool for having specified hole punch size. In
some cases cores are also constructed without yoke bolts.
4. Deburring:
During the process of slitting, cutting and piercing of laminations, the cut
edges get some burrs. These burrs occur mainly during the cutting
operation and are due to following reasons: 1.Shearing blades blunt2.More
clearance between blades3.V-notch tool blunt Presence of burrs impairs the
stacking factor, resulting in gaps, cut into the insulation coatings and bridge
adjacent laminations there by increasing the eddy current losses. These
burrs are removed bypassing the laminations through debarring operations.
5. Annealing and Varnishing:
Annealing is a process of heating and subsequent cooling gradually. During
the process of slitting, debarring, cutting, handling etc., mechanical stresses
are developed inside the laminations that disturb the original grain
orientation and thereby increase the iron loss. This problem is eliminated by
annealing the laminations in roller hearth furnace or batch annealing
furnace at temperature of 810c with a tolerance of 10c preferably in a
neutral atmosphere zone (N2) and subsequently cooled by blast air. The

glass film and phosphate coating uniformly coated on both sides of the
lamination sheets serves as surface insulation. Therefore the laminations
withstand stress relief annealing, without deterioration in its adhesion or
electrical insulation valve, at temperatures upto840c.for this reason we
maintain annealing temperature to less than840c.If the insulation coatings
at the edges are scratched during deburring process or extra varnish
coating is desired, the laminations are processed in a varnishing plant,
which provides a thin coating of varnish and quickly dried up at high
temperatures.
6. Core assembly:
Core building from the finished lamination sheets is done in horizontal
position on specially raised platforms. At first the clamp plates and end
frame structure of one side of the core assembly are laid out. Guide pins are
used at suitable positions for maintaining the proper alignments during core
building process. Oil ducts are formed by sticking strips on lamination and
put in positions required. For each packet, the laminations are
manufactured in two different lengths and these sets are laid out alternately,
keeping at a time two to four laminations together. The two alternate
arrangements provide over-lapping at the corner joints and when the
lamination packets are clamped together, these overlapping edges provide
sufficient mechanical strength in holding the edges in tight grip. After laying
out the complete laminations, the clamp plates and end frame structure of
the other side are laid out and the entire core-end frame structure is
properly secured through bolts and steel bands at a number of positions.
Depending upon the shapes of the formed laminations, different types of
core assemblies can be formed.

COIL WINDING
Windings form the electrical circuit in the transformer. These produce
magnetic flux in the core. These are mainly divided into two parts, one is
primary winding and other is secondary winding. In terms of voltages we
classify them LV Winding and HV winding. The positioning of the HV and
LVwindings with respect to the core is also important from the point of view
of insulation requirement. The low voltage winding is placed nearer to the
core in the case of concentric windings and on the outside positions in the
case of sandwiched windings on account of easier insulation facilities. For
core type transformers the windings are cylindrical and are arranged
concentrically. For shell type transformers the coils are usually rectangular,
around which rectangular shaped core laminations are assembled and
surrounded. The conductors used in transformers may be copper or
aluminium depending upon the customer requirement. Small transformer
with AL winding is cheaper compare to CU winding. However, with increase
in rating and voltage, the transformer with CU winding much cheaper in
overall cost as compared to the transformer with AL winding

The choice of the type winding is largely determined by the rating of the
winding. Some of the common types of windings are described below.
1. Distributed Cross-Over Windings
These windings are suitable for currents not exceeding about 20 A. They
comprise of circular cross section (Fig. 1) and are used for HV windings in
small transformers in the distribution range. A number of such coils are
joined in series, spaced with blocks which provide insulation as well as duct
for cooling.

2. Spiral Windings

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 radia
ducts between turns. Spiral coils are normally wound on a bakelite or
pressboard cylinder (Fig. 2).

Though normally the conductors are wound on the flat side, sometimes
they are wound on the edge. However, the thickness of the conductor should
be sufficient compared to its width, so that the winding remains twist-free
(Fig. 3).

Spiral windings may be made as single layer or multilayer type. Fig 4.

Shows a double layer spiral coil where an oil duct separates the tow layers.
For such a coil, both the start and the finish leads lie at one end of the coil
and may at times prove to be advantageous for making the terminal gear.

Normally it is not necessary to provide ant transposition between the

parallel conductors of a spiral winding as the lengths and the embracing of
leakage flux are almost identical.

3. Helical winding
This type of winding is used in low voltage and high-current ratings. A
number of conductors are used in parallel to form one turn. The turns are
wound in a helix along the axial direction and each turn is separated from
the next by a duct. Helical coils may be single layer (Fig 5) or double layer
(Fig. 6) or multi-layer, if the number of turns are more.

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.

4. Continuous Disc winding

This type of winding is used for voltage between 33 and 132 KV and
medium current ratings. These coils consist of a number of sections placed
in the axial direction (Fig. 7), with ducts between them. Each section is a
flat coil, having more than one turn, while each turn itself may comprise one
or more conductors (usually not more than four or five), in parallel. The
sections are connected in series, but without any joints between them. This is
achieved by a special method of winding. It is not necessary to provide a
cylindrical former for these coils, as these are self-supporting. Each disc is
mechanically strong and exhibits food withstand of axial forces. Another
particular advantage of these coils is that, each section can have either
integral or fractional number of turns for example

5. Transposition
(a) For helical windings, usually three transpositions are provided. The
complete transpositions Fig. 8(a) is provided in the middle of the windings.
Tow partial transpositions are provided, one at 25% of turns Fig. 8(b) and
the other at 75% of turns Fig. 8(c). In complete transposition, each
conductor position is varied symmetrically, relative to the middle point,
whereas in partial transpositions, tow halves of parallel conductors are
interchanged in the positions: The upper have becomes the lower, and vice
versa. Such a transposition needs extra space in the height of the coil.

(b) Wit a multi-start helical winding, the transposition can be achieved by

using rotary transposition. Fig. 9 shows transposition in a double -start

helical winding. By this arrangement, every conductor occupies every

position by turn and thereby complete equalization of impedance is possible.
Also, there is no need for extra space in the coil height.

(c) For disc windings having more than one conductor in parallel,
transposition is made between the conductors by changing their mutual
position at each cross-over from one section to another Fig. (10).

6. Interleaved Disc Winding

A disadvantage with the continuous disc winding is that their strength

against impulse voltages is not adequate for voltages above, say, 145 KV
class. The impulse voltage withstand behaviour of disc coils can be
increased if the turns are interleaved in such a fashion that tow adjacent
conductors belong to tow different turns. Fig. (11) Shows such a winding in
which interleaving has been done in each pair of discs. It will be noticed
that it is necessary to have 2n conductors in hand for winding when n is the
number of conductors in parallel. Conductors of turns 8 and 9 are joined by
brazing. A cross-over is given at the bottom of the disc.

Apart from interleaving between every double-disc, it is also possible to

have more number of discs (say four) in each interleaved group (Fig. 12).

The sequence of manufacture of windings is give below:

1. Loading of molds on the winding machines.
2. Loading of the conductor reels on stands.
3. Dressing of the mould, i.e. assembly of insulation spacers and blocks
on the mound.
4. Manufacture of the winding on horizontal or vertical winding
machines depending on design, type of winding, number of
conductors, to be handled at a time and the type of conductor.
5. Preparation of the leads etc.
6. Dismantling of wining from the machine.

7. Preparatio
n of the
joints
between
conductors.
8. After
removing
the
windings
from the
winding
machine,
each
winding is clamped between top and bottom plates through tie rods,
and kept in an oven for heating. The windings are individually shrunk
to the required axial dimensions by heating in the steam-heated oven
and by applying the required pressure. Heating ensures removal of
moisture from the insulation items. This process is called stabilization
of the winding, and the windings are stabilized to such an extent that
they do not shrink further during service.

Core Coil Assembly:

Core coil assembly consists of assembling the windings to the core
assembly.
Core assembly is placed on a suitable leveled platform. Tighten the
three limbs with webbing tape. Top channels and top yoke laminations
are removed and placed on a table in the same sequence. Bottom
insulation items like press board rings, petals; Parma wood rings are
placed on bottom yoke on each core limb. Core wraps as specified in
the design details are covered to the core limbs and tightened with
cotton tape. LV windings are lowered on each core limb. LV leads
should come to the LV side of the core channels. LV runners,
pressboard cylinder and HV runners are arranged around each LV
coil and tighten them with cotton tape.

HV windings are lowered over LV winding with spacers between each

HV winding. Insulation items like paper tubes, empire sleeves and top
insulation arrangement is completed. During insulation assembly,
various leads are properly position and fully insulated phase barrier
assembly is then completed. Top yoke laminations are assembled back
in position starting with the center step. Top core channels are then
clamped and tightened coils are kept under pressure by tightening tie
rods
3.3TRANSFORMER OIL
Transformer Oil forms a very significant part of the transformer insulation
system and has the important functions of acting as an electrical insulation
as well as coolant to dissipate heat losses. Transformer Oil will be obtained
by fractional distillation and subsequent treatment of crude oil.
Transformer Oil consists of organic compounds namely paraffins,
naphthlenes, aromatics and olefins. All these compounds are hydrocarbons,
so Transformer Oil is a pure hydrocarbon mineral oil.
Transformer Oil has following Characteristics:
Colorless
Low Density
Low Viscosity

Transformer Oil Analysis

Properties of Transformer Oil
Transformer Oil Properties are characterized as
Physical properties
Electrical properties
Chemical properties
Physical Properties
Different physical properties of Transformer Oil are
Moisture Content:
The amount of free and dissolved water present in the oil is its moisture
content and is expressed in p.p.m (parts per million by weight, mg/kg).
Presence of oil is harmful since it adversely affects the electrical

characteristics of the oil and accelerates the deterioration of the insulating

paper. For good Transformer Oil Moisture Content should be low.
Interfacial Tension:
Interfacial Tension is the measure of molecular attractive force between the
oil and water molecules at their interfacial level. By testing for Interfacial
tension we can determine the soluble polar contaminants present in the oil
which reduces the molecular attraction force between the oil and water.
Flash Point:
It is the temperature at which oil gives so much vapour that this vapour
which mixes with the air forms an ignitable mixture and gives momentary
flash on application of the flame under prescribed conditions. A minimum
flash point is specified in order to prevent the risk of fire that might be result
of accidental ignition. For good Transformer Oil Flash Point should be
higher (145 Centigrade).
Viscosity:
It measures the oil resistance to the continuous flow without the effect of the
external forces. The oil must be mobile to transfer the heat in a better
manner from the core to the transformer radiators where heat is
dissipated. So Viscosity of the transformer oil should be very less. With
the decrease in the temperature of the oil viscosity increases, so it is
necessary for transformer oil to have low viscosity at low temperatures.

Pour Point:
The temperature at which transformer oil will just flow under the prescribed
conditions is known as the pour point. Pour Point should be low for good
transformer oil, i.e., transformer oil say at -6deg cent starts just flowing, so
pour point should be low so that oil can start flow even at low temperatures.

Electrical properties:
Different Electrical properties of Transformer Oil are:
Electrical Breakdown Voltage Strength:
Break down Voltage of transformer Oil is the Voltage at which breakdown
occurs between the two electrodes when the oil is subjected to an electrical
field under prescribed condition. Electrical breakdown strength is basic
parameter for insulating system design of the transformer. Transformer Oil
should have higher breakdown Voltage strength. If the transformer has
lower strength it indicates the presence of the contaminating agents like
moisture, fibrous materials, carbon particles, precipitable sludge sediments.

Resistivity:
Resistivity is numerically equivalent to the resistance between opposite faces
of a centimetre cube of the liquid. Insulation resistance of the windings also
depends on the insulation of the oil. For good Transformer Oil resistivity
should be high. Lower Resistivity of Transformer Oil indicates the presence
of moisture and conductive contaminating agents.

Dielectric Dissipation Factor:

Loss angle is an important property of dielectric oil. In ideal dielectric
material the phase angle between the voltage and current is 90.However due
to impurities, certain leakage current flows through the dielectric and actual
phase angle is slightly less than 90. As an angle is very low so tan is also
low.
Dielectric Dissipation Factor is the sine of the loss angle (approximately
equal to the tangent of the loss angle for dielectrics). It is an important
parameter to find the insulation quality of the transformer oil. Dielectric
Dissipation value should be low for good Transformer Oil. Higher
Dielectric Dissipation Factor indicates the presence of moisture and
contaminating agents.
Chemical Properties:
Different Chemical Properties Of Transformer Oil are
Neutralization value:
It is the measure to determine the free organic and inorganic acids present
in the oil expressed in terms of milligrams of KOH required neutralizing the
total free acids in one gram of oil. Oxidation in the transformer oil is due to
reaction between the hydrocarbons present in the oil and air. Copper present
in the copper acts as catalyst to this reaction. The products of oxidation are
injurious to the insulation system of the transformer and corrode the
transformer components. So measurement of the total acidity is the tool to
determine the capability of oil for non-formation of acids during the
life. For good transformer oil Total acidity should be low.

Oxidation Stability:
Oxidation Stability is the measure of neutralization value and sludge after
oil is aged by simulating the actual service conditions of the oil.
Corrosive Sulphur:
Crude petroleum contains sulphur compounds. Most of this s removed at the
time of refining process. Presence of corrosive sulphur results in pitting and
black deposit on the surface of the bare copper used in copper which
hinders the heat dissipation ability.

3.4 TRANSFORMER ACCESSORIES

The various fittings and accessories
used in transformer:
1. Bushings (Porcelain, metal,
oil)
2. Radiators / cooling tube
3. Buchholtz Relay
4. Conservator (Tank & OLTC)
5. Pressure Relief Valve
6. Pressure gauge
7. OTI, WTI, Magnetic oil
gauge
8. Cable boxes
9. OLTC, OCTC circuits
10.Breather
11. Oil inlet valve (oil filtering
valve)
12.Thermometer pocket
13.Explosion vet
14.Change over switch
15.HV fuse link
16.LV circuit breakers

1. Bushing:
A bushing is a hollow electrical insulator through which a conductor may
pass. Bushings are used where high voltage lines must pass through a wall
or other surface, on switchgear, transformers, circuit breakers and other
high voltage equipment.
The bushing is a hollow insulating liner that fits through a hole in a wall or
metal case, allowing a conductor to pass along its centre and connect at
both ends to other equipment. The purpose of the bushing is to keep the
conductor insulated from the surface it is passing through. Bushings are
often made of wet-process fired porcelain, and may be coated with a semiconducting glaze to assist in equalizing the electrical stress along the length
of the bushing.
The inside of the bushing may contain paper insulation and the bushing is
often filled with oil to provide additional insulation. Bushings for mediumvoltage and low-voltage apparatus may be made of resins reinforced with
paper. The use of polymer bushings for high voltage applications is
becoming more common. The largest high-voltage bushings made are
usually associated with high-voltage direct-current converters.

2. Conservator Tank
Tank which is use to connected outside of the
transformer. It is a small drum mounted over
the top of the main tank. It is connected
through a pipe to the transformer tank
containing oil. The function of the
conservator is to take up the expansion and
construction of the oil with changes of
temperature in service, without allowing the
oil to come in contact with the air, for which
it is liable to take up moisture.

3. Buchholz relay
It is a safety device, which trips off the transformer circuit in case of short
circuit or an excessive heat in the cores and oil etc. it is connected in
between the transformer tank .When oil is decomposed due to an internal
fault, gases are produced; oil vapour is produced at high or short circuit
among windings, the Buchholz relay is operated
The core legs and yokes are braced by means of fibre glass epoxy bands.
The top and bottom yokes braced with suitable steel beams. Later designs
constructed the core by stacking layers of thin steel laminations, a principle
that has remained in use. Each lamination is insulated from its neighbours
by a thin non-conducting layer of insulation. The effect of laminations is to
confine eddy currents to highly elliptical paths that enclose little flux, and so
reduce their magnitude.
4. Tap Changer
There are
device
Tap
Changer
are use
change
winding

special
call
which
to
the
of

transformer in high voltage side. Configuration of Tap changer is given in

Figure 2.6. A transformer tap is a connection point along a transformer
winding that allows the number of turns to be selected. Selection of the tap
in use is made via a tap changer mechanism. By using Tap Changer device
11kv voltage can be controlled. There are different Tap positions according
to different voltage levels.

It has following parts1. Tap changer type M

2. Motor drive MA7
3. Protective relay RS2001
4. Drive shaft and bevel gear
5. Breather
The breather is provided at the entrance of the conservator of oil immersed
equipment such as Transformers and reactors. Breather removes the
moisture and dust in the air inhaled and prevents the deterioration of the
Transformer oil due to moisture absorption. The breather uses silica - gel as
the desiccating Agent and is provided with an oil pot at the bottom to filtrate
the inhaled air.

3.5Transformers manufacturing at BHEL

BUSHING AND CYLINDERS

52KV TO 525 KV OIP condenser Bushings up to 3150
amps. Rating

25 kV, up to 300 amps. Bushing for Indian Railways.

Bushing for miscellaneous applications such as

bushings, roof bushings, T.G. bushings etc. To suit customer
requirements.

SRBP cylinders for transformer application up to 1400

mm I/D, up to 2400 mm long.

CAPACITORS
Shunt Capacitor banks with all film dielectric
impregnated with non PCB Impregnate of desired ratings from
6.6 to 400 kV complete with manual / automatic control
equipment for Industrial and power system application.

Pole mounted Capacitors for mounting in line with Rural

Electrification scheme up to 11 KV

Roof Capacitor in Traction Motor application: 4

microfarad, 2 KV DC

Series capacitors for Reactive compensation and voltage

regulation in power system from 33kV to 400 KV

Capacitor to improve power factor
substations suitable for Railway Electrification.

of

traction

Surge Capacitor for protection of Rotating Machine and

Generator transformers winding 15 kV and 40 kV, 0.125 micro
farad.

AC filter Capacitor for Harmonic filtering suitable for

HVDC application up to 500 kV.

Coupling capacitors / CVT up to 800 kV class for Power

line carrier communication application, meeting and protection.

TRANSFORMERS
Power Transformers upto 420kV class, 50/60 Hz 930
MVA, 3-phase Bank.

Power Transformers upto 420kV class, 50/60 Hz 400

MVA,
3-phase Unit.

HVDC Converter Transformers and Smoothing Reactors.

500 MVA, 500kVDC, 3 winding, 1- Phase. Convertor

Transformer.

254 MVAR, 360mH, 1568A, 500 kVDC 1 Phase

Smoothing Reactor.

INSTRUMENTS TRANSFORMERS

Current transformers up to 400 kV.

Capacitor voltage Transformer up to 420 kV.

REACTORS
Gapped core Shunt Reactors up to 420 kV class, 125
MVAR 3 Phase Unit.

Series and Neutral Grounding Reactors.

Controlled Shunt Reactor up to 420 kV class, 80 MVAR 3

Phase Unit.

ULTRA HIGH VOLTAGE LABORATORY

The DC test plant is adequate for test levels suitable up
to +800 kV HVDC transmission.

Suitability for testing AC equipments up to 1200KV

class.

FOR POWER TRANSMISSION

kV,

Control for protection Panels for substations up to 400

distribution feeders and capacitors banks.
OLTC control panels.
Controls for Nuclear Power Plants.

Testing Facilities
Conforming to IS 2026/ IEC 76
Ultra High Voltage (UHV) Shielded, Acoustically treated Laboratory
35x67x35 m (H) Hall - One of the biggest in Asia and in World with a
Manufacturer.
4 MV, 400kJ, Impulse Generator
3600kV Potential Divider

 High Resolution Impulse analyzing System

1200kV, 30mA HVDC Test System for DC Testing of converter
Transformers & Smoothing Reactors
1500kV, Cascade connected, 50 Hz AC Test Transformer
1500kV, AC Potential Divider
160 MVA, 66/650kV, 3 Phase Testing Transformer
2 MVA (50 - 180 Hz), 40 MVA (50 Hz) & 9 MVA (50 - 200 Hz),
Synchronous Motor Generator Set
DC Test set-up for Plotting V/I Characteristic of Shunt and Smoothing
Reactors
Full-fledged Calibration and Testing Laboratory for Instruments and
Materials
The testing facility are being augmented by adding the following
facilities designed & manufacture in - house :
300 MVA 650 kV testing transformer.
180 MVA 138/1200 kV testing transformer.
40 MVA 156 kV testing transformer.

Manufacturing Facilities
Core & Punch
Highly accurate gang slitting machine which can slit minimum25 mm
and maximum 850 width from a roll. Slitting capacity 14 Tons per
day.
Two nos. cropping machines capable to crop 14 Tons per day with a
maximum burr of 30 microns. Minimum 55 mm and Maximum 750
mm width can be cropped.

 2 No. CNC cropping line for 1000 mm width laminations having

speed accuracy of 0.2 mm.
3 No. Core building platform of size 5000 mm X 6000 mm on which a
core up to 300 Tons can be built.
One very accurate and sophisticated Resin Impregnation and Vacuum
plant to impregnate cores.
Winding
Fourteen numbers Vertical winding machine on which a winding for
2600 mm O/D and 300 Tons can be built.
26 numbers Horizontal winding machines capable of any type of
winding upto O/D of 3000 mm and height of 3600 mm.
300 Tons/500 tons (2 No.) coil pressing Hydraulic press.
One number coil reversing cradle for safe reversing of coils.
Eight numbers high frequency Induction Brazing machines to braze
joints in coil winding area.

Processing
3 NO. 400 KW Vapor phase plant with drying unit.
2 No. Conventional Vacuum Plant.
3 No. transformer oil filtration and degassing plant.
2 No. Oil Circulating Plant.
2 No. 250 Tons EOT cranes.
Aero Caster movement system for handling coils & complete
transformers.

 Isostatic press 250 Tons for coil stabilization

A well equipped insulation shop with facilities like circular saw,
guillotine, band saws, rolling/bending and scarifying facilities, hot and
power presses and currying oven etc.

4. TESTING OF TRANSFORMER
Tests and evaluation definitions are listed below:
There are mainly two types of test;
1. Type Test
2. Routine Test
A. Routine Tests:
1. Measurement of winding resistance
2. Measurement of voltage ratio and check of phase displacement
3. Measurement of short-circuit impedance and load loss
4. Measurement of no-load loss and current
5. Dielectric tests
6. Separate source AC withstand voltage test
7. Induced AC voltage test
8. Partial-discharge measurement
9. Tests on on-load tap-changers

B. Type Tests:
1. Temperature-rise test
2. Lightning-Impulse tests
C. Special Tests:
1. Switching impulse voltage test
2. Measurement of dissipation factor (tan ) and capacitance
3. Measurement of zero sequence impedance(s)
4. Determination of sound level
5. Measurement of harmonics of the no-load current

6. RECTIFIER ASSEMBLY

Large Current Rectifier:

A basic rectifier unit consists of a regulating transformer, one or two
rectifier transformer having configuration of double star with IPT or 3phase bridge connections, transducers having variable voltage
characteristics and one or two rectifier cubicle. The voltage range required

for starting and controlling the output of the process is obtained with the
help of transducers in conjunction with an on load tap changer mounted on
regulating transformer.
The large current is achieved by power diodes connected in parallel on a
heat sink for each phase. The heat sinks are either forced air cooled or
forced de-mineralized water cooled depending upon rating and application.
The equipment comprises an assembly of silicon diodes on heat sinks
together with protection components, all suitably enclosed and separately
mounted transformers. Additional items such as inter connections, control
cubicles, switchgear, AC/DC measuring system, AC/DC bus bars are
included to specification when required.
For large current applications above 25kVA important advantages are
gained by mounting the rectifier assembly in close association, with the
transformers known as Rectiformers. The choice of connections depends
on the dc voltage required, efficiency & cost considerations.

Industrial applications of large current rectifiers:

Factory general DC supplies

DC supplies to industrial Machines & processes

Electro-plating

Aluminium smelting

Caustic Soda plant

Graphite furnace.

SWITCHGEAR :
INTRODUCTION:

The term switchgear, commonly used in association with electric power

system, or grid, refers to the combination of electrical disconnect and/or
circuit breaker used to isolate electrical equipments. Switchgear is used
both to de-energize equipments to allow work to be done and to clear faults
downstream.

LOCATION:
Switchgear is located anywhere that isolation and protection may be
required. These locations include generators, motors, transformers, and
substations.

SUBSTATION:
Typically switchgear in substations is located on both the high voltage and
the low voltage side of large power transformers. The switchgear located on
the low voltage side of the transformer in distribution type substations, now
are typically located in what is called a power distribution centre (PDC).
Inside this building is typically smaller, medium voltage (~15kv) circuit
breaker feeding the distribution system. Also contained inside these power
control centre are various relays, meters, and other communication
equipment allowing for intelligent control of substation.

HOUSING:
Switchgear for low voltages may be entirely enclosed within a building. For
transmission levels of voltages (high voltages over 66kv) often switchgear
will be mounted outdoors and insulated by air, though this requires a large
amount of space. At small substations, switches may be manually operated,
but at important switching stations on the transmission network all devices
have motor operators to allow for remote control.

A piece of switchgear may be a simple open air circuit breaker or it may be

insulated by some other substance. An effective although more costly form of
switchgear is gas insulated switchgear (GIS), where the conductors and
circuit breakers are insulated by pressurized (SF6). Another common type is
oil insulated switchgear. Vacuum circuit breakers are frequently used as
medium voltage switchgear (up to 35kv).

FUNCTIONS:
One of the main function of switchgear is protection: discrimination
between circuit breakers enhance availability, that is to say continuity of
service. The overall approach is termed coordination: the standard provides
a framework or discrimination and cascading that protects the integrity of
power system and minimizes the scope of downstream outrages.
Protection is needed along with high degree of reliability with system
operations. We have to protect system from the faults like overloads, under
voltages, over voltages etc. So we need switching devices for making and
braking of the circuit.

Metal
enclosed
indoor
vacuum
circuit breaker
switch board

VM12

Up to 12kv, 3000A,
44kA

>Power
station &
process
industry
auxiliaries
>distribution
duty (width
700mm)

Description

Metal
enclosed
indoor
vacuum
circuit breaker
switch board

BVM12

Up to 12kV, 1250A, Distribution

26.3kA
duty (width
550mm)

Outdoor metal
enclosed
vacuum
circuit breaker
switch board

VMN12

Up to 12kV,
1600A,25kA

Distribution
duty

Metal clad
indoor
vacuum
circuit breaker
switch board

VM24/36

24kV/36kV up to
2500A, 25kA

Distribution
duty

Outdoor
structure
mounted
porcelain clad
vacuum
breaker

PVN12A

12kV, up to 1250A,
25kA

Distribution
duty (the
circuit
breakers can
be provided
with the
outdoor relay
panel, outdoor
structure
mounted
instrument
transformer
&isolator)
suitable for
8MVAR/
capacitor
bank
switching

Outdoor
structure
mounted
porcelain clad
vacuum circuit
breaker

Outdoor role
mounted auto
enclosure with
microprocessor
based control

PVN36

PMVN

36kV, up to 2000A,
25kA

Distribution
duty (the
circuit
breakers can
be provided
with outdoor
relay panel.
Outdoor
structure
mounted
instrument
transformer &
isolator).
Suitable for
44MVAR/
capacitor
bank
switchcing

12kV, 400A, 12.5kA

Auto
reclosing
unattended
rural feeder
built in CT &
Auxiliary
transformer is
provided

Outdoor pole
mounted
vacuum type
capacitor
switch

PWVC

12kV, 200A, 6kA

Switching of
capacitors.
The switch is
provided with
electronics
control unit
for switching
command
based on the
load currents.
Built in
auxiliary
transformer &
CT provided

Outdoor poles
mounted
vacuum
setionaliser

PWVS

12kV, 400A

Sectionalizing
of faulty
feeder

Outdoor
porcelain clad
vacuum switch

PVTI

25kV, 800A, 8kA

Traction
substation
duty

Outdoor
porcelain clad
vacuum circuit
breaker

PVTB

25kV, 1600A,20 kA

Traction
substation
duty

Indoor metal
clad SF6 gas
insulated
vacuum
chamber

GVM36

36kV, Upto 1600

A,25 kA

Distribution
duty(width
650mm)

Outdoor metal
clad skid
mounted
switchgear

MVM12

Up to 12 kV,1250
A,25kA

Electric
distribution
substation for
open cast
mines

Outdoor metal
clad KIOSK

VN12

12kV,1250A,25KA

Distribution
duty

Spark Gap

SG

220kV,3phase,50Hz,
STC 31.5kA

Series
compensation

Types
A piece of switchgear may be a simple open-air isolator switch or it may be
insulated by some other substance. An effective although more costly form of
switchgear is gas insulated switchgear (GIS), where the conductors and
contacts are insulated by pressurized sulfur hexafluoride gas (SF6). Other
common types are oil or vacuum insulated switchgear.
The combination of equipment within the switchgear enclosure allows them
to interrupt fault currents of thousands of amps. A circuit breaker (within a
switchgear enclosure) is the primary component that interrupts fault
currents. The quenching of the arc when the circuit breaker pulls apart the
contacts open (disconnects the circuit) requires careful design. Circuit
breakers fall into these four types:

Oil
Oil circuit breakers rely upon vaporization of some of the oil to blast a jet of
oil through the arc.

Gas
Gas (SF6) circuit breakers sometimes stretch the arc using a magnetic field,
and then rely upon the dielectric strength of the SF6 to quench the stretched
arc.

Vacuum
Vacuum circuit breakers have minimal arcing (as there is nothing to ionize
other than the contact material), so the arc quenches when it is stretched to
a very small amount (<23 mm). At or near current zero the arc is not hot
enough to maintain a plasma, and current ceases; the gap can then
withstand the rise of voltage. Vacuum circuit breakers are frequently used in

modern medium-voltage switchgear to 35,000 volts. Unlike the other types,

they are inherently unsuitable for interrupting DC faults.

Why vacuum circuit breakers are the

best choice?
Freedom from oil, recluse gases eliminates the arching and fire
hazard.
Sealed for life design of interrupts make the vacuum interrupter and
the vacuum circuit breaker practically maintenance free.
Low arc energy and arching time results in very long contact life.
Rapid dielectric recovery requirements results in quiet and low
vibration operations. Reduced number of component imparts
simplicity to the operating mechanism.
No change in contact resistance because of the contact pressure
applied. The very low contact resistance remains practically constant
regardless the number of switching operation carried out.
Furthermore the fact that the contact cannot oxidize in vacuum
ensures that they remain metallically clean on maintenance necessity.
No capital cost on maintenance necessity.
Switching in vacuum doesnt produce any by-product. The
hermetically sealed vacuum interrupters ensure that there is no
interaction with the environment and these results in a stable
dielectric medium.

11 KV SWGR ASSEMBLIES

In a power system SWGR serves two purposes:

1) Switching during normal condition for maintenance.
2) Switching during abnormal condition or fault in the system for protection.
SWGR is a modified form of MCB (miniature circuit breaker) which is used
for higher voltages. The 11kV assembly is used for indoor purpose. It has a
fixed and moving contact. It has the following chambers:
1) Breaker chamber: It is the main part of the SWGR where the circuit
makes and breaks. It has a moving portion called truck. The
mechanism used for the operation of
VCB has a universal d.c. motor; limiting switches
operation, position indicator etc.
2) Instrument chamber: It consists of controlling devices. Its is a low
voltage chamber having relays, fuses etc.
3) CT chamber: It has three current transformers to measure the
current.
4) Bus bar chamber: It is welded sheet steel construction and covers
bus bar of aluminium or copper electroplated with silver.

OPERATION:
When the spring is discharged the limiting switch
becomes ON. This switch current to universal motor and
it starts operating. The spring is charged by the motor.
When we have to close the breaker we push the close
button, spring discharges with force and gives motion
to the shaft, lever and drive link.
This makes contact with fixed and moving contact of
breakers. The movement charges the tripping spring and
contact pressure spring are charged. The recharging of
closing spring is done as above again in similar manner.

ON LOAD TAP CHANGER

OLTC perform voltage regulation of power transformer by varying the

transformer ratio under load without interruptions. Operation is carried out
in steps, therefore, transformer winding is provided with taps which are
connected to the tap selector of the tap changer.
Tap changer is designed for oil immersed installation into the transformer
main tank to allow for tap leads being as short as possible between winding
and tap changer.
It has following parts5. Tap changer type M
6. Motor drive MA7
7. Protective relay RS2001
8. Drive shaft and bevel gear

TAP CHANGER TYPE M

OLTC consists of diverter switch installed into a pressure tight oil
compartment separated from transformer oil and tap selector mounted
below it.
Tap changer is attached to the transformer cover by means of the tap
changer head which also means of the tap changer head which also serves
for coupling the drive shaft and for connecting a pipe to the oil
conservator. If required the tap selector may be equipped with a change
over selector. Models without change over selector are available up to 18
and with changeover selector up to 35 operating positions.
On load tap changer M is available in following3 pole tap changer

: M III 350, M III 500, M III 600

Single pole tap changer

M I 1500, M I 1800

: M I 351, M I 501, M I 601, M I 802, M I 1200,

MOTOR DRIVE MA7

The motor drive serves for driving the tap changer to the selected service
positions. The motor drive housing contains all mechanical and electrical
parts necessary for the tap changer. It follows step by step principle.
Over running at the end positions is prevented by electrical and
mechanical limit switches.

Technical specificationsMotor : 1.1kw, 415v, 3ph, 2.75A, 50Hz, 1500rpm

Revolution of driving shaft per

: 33

Switching operation
Running time per switching

: 5 sec

Operation
Revolution of hand crank per

: 33

Switching operation
Voltage
For control

: 110 V ac

For heater

: 240 V ac

Input of control circuit

running time)

: 65 Vamp (during

Insulation level
( except for driving motor)

: 2 KVrms,1 min

Weight

: 90 kg

Design of Motor drive unit

The motor drive housing is made of corrosion proof light metal casting and
is suitable for out-door application protected to IP 55 as per IS : 13947(Pt1),1993. The gearing consists of the Belt Drive transmission system and
control gear. The control gear is fixed to one side of the transmission
system. It comprises a cam disc for operating the switches, the tap change
indication wheels as well as the cam disc make one revolution per tap

change operation. The green zone indicates the rest position of the cam
switches. The setting position for initial starting is indicated by the red
center mark in green zone. A mechanical counter records the switching
operations performed. A hand crank having a plastic handle is provided
outside the housing and attached by wing out clamps.

The electrical equipments inside the standard motor drive and

comprise the following:
1. Motor protective switch with thermic and magnetic tripping, three
pole design with two auxiliary contacts (1No + 1NC),having open
circuit remote tripping facility
2. Push buttons for raise/lower control
3. having two contacts (1NO + 1NC)
4. MCB for control supply
5. MCB for heater supply
6. Door switch
7. Illumination lamp
8. Auxiliary transformer 415/55-0-55V 500VA
9. local/remote control selector switch, 6A,2 pole
10. Push button for tripping the motor protective switch Q61 having two
contacts (1NO+1NC) and lamp socket (for lamp H61).
11. Limit switches for position n/position 1, 3 pole design for 415 Volts
A.C., 25 amps.
12.Hand Interlock safety switch for manual operation; 3 pole design for
415 volts A.C., 25 amps,
13.Cam switches for control direction raise (toward position
n,)/Lower (toward position 1), two pole changeover switch (1NO +
1NC Contact with a common switch over point).
14.Cam switch for step-by-step operation same as S71.
15.Motor Contactors for Control direction Raise (towards position n)/
Lower (towards position 1),three pole design, auxiliary contacts
2NO + 2NC.

16.Brake contactor, contacts 5 NO +5 .NC

17.Auxiliary contactor for step-by-step operation, contacts 4NO + 4NC
18.Thermostat, setting range 0 to +30o C.
19.Driving motor, squirrel cage rotor, rating as per technical data.
20.Heater-1600Ohms
21.Heater-600Ohms
22.Resistance position transmitter for crossed coil instrument (100 Ohms
per step)
23.Change-over switch for parallel operation
24.Position transmitter (spare)
25.Contact for passage of position (optional)
26.Socket & Socket Switch

Protective Relay RS 2001

The protective relay serves for preventing tap changer and transformer
being seriously damaged during failure. It is, therefore, always a part of our
supply along with the tap changer. The protective relay has to be connected
in such a way that the transformer is immediately switched off when the
relay is energized.
Technical data:
Housing

Outdoor design (Protection IP55)

Relay drive

Flap valve with aperture

Critical oil flow

For Tripping the

Flap Valve (at 20C)

1m/s 20%

Switch

Reed contact, 1 No

Switch rating

3 amps, 24 to 250V A.C., 400 VA

3 amps, 24 to 250V D.C., 250 W

Test voltage to
Ground

2 kV, 50 Hz, 1min.

Shock-proof
Weight

:
:

Up to 3 g
3.5 kgs.

Design:
The housing consists of corrosion-proof light metal alloy and is provided
with two flanges for connecting pipes leading to the tap changer head and to
the oil conservator. For checking the tripping function of the relay as well as
for subsequently resetting the flap valve, two test push-buttons are installed
in the terminal box. The terminals are covered by a plastic screen. The relay
drive element consists of the flap valve with attached permanent magnet.
The magnet actuates the reed contact and serves for fixing the flap valve is
not possible. The protective relay is energized by an oil flow from the tap
changer head to the oil conservator only. The oil flow operates the flap
valve being tripped into the off position. The reed-contact is actuated to
trip the transformer circuit breaker. The protective relay is not energized
when the tap changer is operating under nominal load or permissible
overload. Following are the images of a protective relay.

Drive shaft and bevel gear

unit:
The square driving shaft is a mechanical connection between motor drive
and tap changer head. The bevel gear connects the vertical and horizontal
parts of the above shaft. The vertical shaft has to be mounted between the
motor drive unit and the bevel gear and the horizontal part between bevel
gear and tap changer head. The drive shaft couplings are the same for both
parts. Both ends of the square shaft are connected to the respective part by
two coupling brackets and one coupling bolt. The square shafts are
delivered over size (various standard lengths) and have to be cut to the
required length when they are mounted on the transformer.

FUNCTIONOn-load tap changers serve for the voltage regulation of power

transformers by varying the trans-former ratio under load without
interruption. Operation is carried out in steps. Therefore, the transformer
winding for regulation purposes is provided with taps which are connected
to the tap selector of the changer.
The tap changer is designed for oil-immersed installation into the
transformer main tank (Fig-1) to allow for tap leads being as short as
possible between winding and tap changer. The tap selector serves for
selecting the desired tap which is connected to the diverter switch side not
yet under load. The subsequent diverter switch action causes this tap to
carry load current. The function of diverter switch and tap selector must be,
therefore, properly aligned during tap change operating sequence. Tap
change operation is initiated by starting the motor drive. Tap changer head
and motor drive are coupled mechanically by a drive shaft. The diverter
switch and the tap selector which both operate on high-voltage potential
are driven from there. The mechanism of the tap changer is designed to
carry out a complete tap changer operation after defined number of
resolutions performed on the tap changer hand drive shaft in one direction.
The motor drive stops automatically after the tap change operation is
complete (step-by-step principle).

TRANSFORMER

SWITCH GEAR ,
CONTROL GEAR
& RECTIFIER

CONTENTS
A>SWITCHGEAR
Introduction
Range of Products
VCB
11KV Assembly
11/33 KV Assembly

B>CONTROL GEAR ASSEMBLY

C>on load tap changer