Thapar institute of engineering

and technology, Patiala

TRAINING REPORT ON

‘POWER TRANSFORMER’

Duration of Vocational Training- 04th June, 2018 to 14th July, 2018

BHARAT HEAVY ELECTRICALS LIMITED

BHOPAL

Training guide: Submitted by:

Mr. SUMIT KUMAR ANKITA ANAND
Dy. Manager B.Tech (ELE)
MM-MOD Roll No: 101604025
BHEL, Bhopal T.I.E.T, Patiala
Token No: VT-2018/824

1
 BHARAT HEAVY ELECTRICAL LIMITED
PIPLANI, BHOPAL MP-462022, INDIA

CERTIFICATE
This is to certify that Miss. Ankita Anand student of 2nd year, Electrical
Engineering, Bachelor of Technology, Thapar Institute of Engineering and
Technology, Patiala has undergone her Vocational Training from 04th June
2018 to 14th July 2018 in MOD under my guidance.
Miss Ankita Anand has successfully completed her training and submitted
the training project report. During the period of training she was found
sincere, punctual & regular. Her conduct and behavior was very good.

SUMIT KUMAR
Dy. Manager
MM-MOD
BHEL, Bhopal

2
 ACKNOWLEDGEMENT
Every project big or small is successful largely due to the effort of a number
of wonderful people who have always given their valuable advice or lent a
helping hand. I sincerely appreciate the inspiration, support and guidance of
all those people who have been there in making this project and our summer
training a successful one.
I am extremely grateful to the “BHARAT HEAVY ELECTRICALS Ltd.,
Bhopal” for the confidence bestowed in me and allowing me to held the
summer training during the duration from 04th June 2018 to 14th July 2018.
At this juncture I feel deeply honored in expressing my sincere thanks to
each and every employee for making the resource available at right time and
providing the valuable insights leading to the successful completion of my
project.
I express my gratitude to Mr. Rajesh Pathak for arranging the summer
training in good schedule. I also extend my gratitude to my project guide Mr.
Sumit Kumar, who assisted me in compiling the project and also helped
throughout my vocational training period to make my learning much better.
I would also like to thank all the faculty members of Thapar Institute of
Engineering and Technology, Patiala for their critical advice and guidance
without which this project would have not been possible.
Last but not the least I place a deep sense of gratitude to my family members
and my friends and the employees of the BHEL, Bhopal who have been a
constant source of inspiration during the preparation of this project.

NAME: ANKITA ANAND

DATE: 14th JULY 2018
PLACE: BHOPAL

3
 Table of contents
S. NO. TOPICS PAGE NUMBER
1. INTRODUCTION 6-12
 BHEL, Bhopal 6-7
 Products of BHEL 8-9
 BHEL Campus 9-10
 BHEL Contribution in Different Sectors 10-12
 Vision, Mission and Values 12
2. PRODUCTS OF BHEL, BHOPAL 13-19
 AC Motors and Alternators 14
 Transportation Equipments 14
 Hydro Generator 15
 Excitation Control Equipment 15
 Steam Turbine 15
 Oil Rigs 15-16
 Transformer 16
 Switchgear 16
 On Load Tap Changer 17
17
 Large Current Rectifier
18
 Control and Relay Panel
18
 Maintenance of Thermal Power Station
19
 Fabrication
3. POWER TRANSFORMER 20-38
MANUFACTURING
 Introduction 20-21
 Stages of Power Transformers Manufacturing 22
 Main Parts of Transformer 22-26
 Core Manufacturing Process 27-28
 Flow Chart for Core Formation 28
 Winding 28
 Winding Conductor 29
 PICC 29
30
 CTCC
30
 Spiral Winding
31
 Helical Winding
31-32
 Interleaved Disc Winding 33
 Processing of Winding 34
 Process Map of Transformer Manufacturing 34-35
4
  Core and Coil Assembly
 Processing of Core and Coil Assembly 35
 Drying Out Process 35
 Tank Fabrication and Fitting 36
 Equipments used for the Protection of Power 37
Transformer
 HVDC Transformer 37
 Tests on Transformer 38
4. BUSHING MANUFACTURING 39-44
 Introduction 40
 Classification of Bushings 40-41
 Bushing Design 41-42
 Insulating Material 42-43
 Constructional Details and Main Parts of 43-44
Bushing
5. REFERENCES 45

5
 INTRODUCTION
BHEL is an integrated power plant equipment manufacturer and one of the
largest engineering and manufacturing company in India in terms of
turnover. It was established in 1956, ushering in the indigenous Heavy
Electrical Equipment industry in India - a dream that has been more than
realized with a well recognized track record of performance. The company
has been earning profits continuously since 1971-72 and paying dividends
since 1976-77.
Government of India (Ministry of Heavy Industries and Public enterprises)
has granted the status of MAHARATNA to Bharat Heavy Electricals
Limited on 1st Feb 2013.
It has been engaged in the design, engineering, manufacturing, construction,
testing, commissioning and servicing of a wide range of products and
services for the core sectors of the economy, viz. Power, Transmission,
Industry, Transportation (Railway), Renewable Energy, Oil, Gas and Defense .
BHEL have a share of 59% in India’s total installed generating capacity
contributing 69% (approx.) to the total power generated from utility sets
(excluding non-conventional capacity) as of March 31, 2012.
BHEL’s greatest strength is the highly skilled and committed workforce of
49,390 employees. Every employee is given an equal opportunity to develop
himself/herself and grow in his/her career. Continuous training and
retraining, career planning, a positive work culture and participative style of
management. All these have engendered development of a committed and
motivated workforce setting new benchmarks in terms of productivity,
quality and responsiveness.

BHEL, BHOPAL
Bharat Heavy Electricals Ltd was set up in 1956 at Bhopal. There are around
10,000 employees at the BHEL plant in Bhopal being a vital part of BHEL on a
whole.
Bharat Heavy Electricals Ltd. Bhopal is situated near Piplani which is a
nowadays covers large part of Bhopal. BHEL TOWN, Bhopal is a suburb of
Bhopal, Madhya Pradesh. This has developed like other BHEL townships
after Indian public sector engineering company BHEL started its operations
here. It is spread over an area of around 20 km2 and provides facilities like
parks, community halls, library, shopping centers, banks, post offices, etc.
6
The company has been earning profits continuously since 1971-72 and
paying dividends uninterruptedly since 1976-77. In recognition of its
consistent high performance, BHEL has been conferred with the 'Maharatna'
status by the Government of India on 1st February 2013.
It is now one among seven Maharatna PSUs with a widespread network of 17
manufacturing units, 2 repair units, 4 regional offices, 8 service centers, 8
overseas offices, 15 regional centers, 7 joint ventures, and infrastructure to
execute more than 150 project sites across India and abroad, BHEL provides
products, systems and services to customers efficiently and at competitive
prices. The company has established capability to deliver 20,000 MW p.a. of
power equipment to address the growing demand for power generation
equipment. With an export presence in more than 76 countries, BHEL is truly
India’s industrial ambassador to the world.

Aerial View of BHEL, Bhopal

The high level of quality & reliability of our products is due to adherence to
international standards by acquiring and adapting some of the best
technologies from leading companies in the world including General Electric
Company, Alston SA, Siemens AG and Mitsubishi Heavy Industries Ltd.,
together with technologies developed in our own R&D centers.
Most of BHEL’s manufacturing units and other entities have been accredited
to Quality Management Systems (ISO 9001:2008), Environmental

7
Management Systems (ISO 14001:2004) and Occupational Health & Safety
Management Systems (OHSAS 18001:2007).

PRODUCTS OF BHEL
 Thermal power Plants
 Nuclear power Plants
 Gas based power Plants
 Hydro power Plants
 DG power Plants
 Boilers (steam generator)
 Boiler Auxiliaries
 Gas generator
 Hydro generator
 Steam turbine
 Gas turbine
 Hydro turbine
 Transformer
 Switchgear
 Oil field equipment
 Boiler drum
 Piping System
 Soot Blowers
 Valves
 Seamless Steel Tubes
 Condenser s and Heat exchangers
 Pumps
 Desalination and Water treatment plants
 Automation and Control systems
 Power electronics
 Transmission system control
 Semiconductor devices
 Solar photo voltaic
 Software system solutions
 Bus ducts
 Insulators
 Control panels
 Capacitors
8
  Bushings
 Electrical machines
 DC, AC heavy duty Motors
 Compressors
 Control gears
 Traction motors
 Research and development products

BHEL CAMPUS
 Added more than 124000 MW to the country's installed power
generating capacity so far.
 Supplied over 25000 Motors with Drive Control System to power
projects, Petrochemicals Refineries, Steel, Aluminum, Fertilizer, Cement
plant, etc.
 Supplied Traction electrics and AC/DC locos over 12000 km Railway
network.
 Supplied over one million Values to Power Plants and other Industries.
 BHEL has retained its market leadership position during 2013-14 with
72% market share in the Power Sector, even while operating in a
difficult business environment. Improved focus on project execution
enabled BHEL record highest ever commissioning/synchronization of
13,452 MW of power plants in domestic and international markets in
2013-14, marking a 30% increase over 2012-13.
BHEL has been exporting our power and industry segment products and
services for over 40 years. BHEL's global references are spread across over
76 countries across all the six continents of the world. The cumulative
overseas installed capacity of BHEL manufactured power plants exceeds
9,000 MW across 21 countries including Malaysia, Oman, Iraq, the UAE,
Bhutan, Egypt and New Zealand. Our physical exports range from turnkey
projects to after sales services.
In the world power scene BHEL ranks among the top ten manufacturers of
power plant equipment, spectrum of products and services offered, it is right
on top. BHEL’s greatest strength is its highly skilled and committed
workforce of 48,399 employees. Every employee is given an equal
opportunity to develop himself/herself and grow in his/her career.
Continuous training and retraining, career planning, a positive work culture
and participative style of management - all these have engendered
development of a committed and motivated workforce setting new
9
benchmarks in terms of productivity, quality and responsiveness. BHEL
business operations cater to core sectors of the Indian Economy like Power,
Industry, Transportation, Transmission, and Defense.
BHEL BHOPAL is broadly divided into 9 BLOCKS:
 BLOCK-1 Water Turbine Manufacturing
 BLOCK-2 Heavy Electrical Machine and IMM and LEM
 BLOCK-3 Transformer, Capacitor and Bushing Manufacturing and Ultra
High Voltage Testing.
 BLOCK-4 SCR (Switchgear, Control Gear and Rectifier)
 BLOCK-5 Coil & Insulation Manufacturing
 BLOCK-6 Steam Turbines
 BLOCK-7 Traction Motors & Alternators
 BLOCK-8 Fabrication
 BLOCK-9 Transportation group(Traction Motors And Alternator)

BHEL’S CONTRIBUTION IN DIFFERENT SECTORS

 POWER SECTOR: Power sector comprises thermal, nuclear, gas &
hydro power plant business. Today, BHEL supplied sets account for
nearly 56,318 MW or 65% of the total installed capacity of 86636 MW
in as against nit till 1969-1970. BHEL has proven turnkey capabilities
for executing power projects from concept to commissioning. It
possesses the technology and capability to produce thermal power
plant equipments up to 1000MW rating and gas turbine generator sets
up to a unit rating of 240MW.
Cogeneration and combined cycle plants have been introduced to
achieve higher plant efficiencies. To make efficient use of the high ash
content coal available in India, BHEL supplies circulating fluidized bed
boilers to thermal and combined cycle power plants.
BHEL manufacturers 235 MW nuclear turbine generator sets and has
commenced production of 500 MW nuclear turbine generator sets.
Custom-made hydro sets of Francis, Pelt on and Kaplan types for
different head-discharge combinations are also engineered and
manufactured by BHEL is based upon contemporary technology
comparable to the best in the world & is also internationally
competitive.
 TRANSMISSION: BHEL also supplies a wide range of transmission
products and systems up to 400 KV Class. These include high voltage
power and distribution transformers, instrument transformers, dry
10
 type transformers, SF6 switchgear, capacitors, and insulators etc. For
economic transmission bulk power over long distances, High Voltage
Direct Current (HVDC) systems are supplied. Series and Shunt
Compensation Systems have also been developed and introduced to
minimize transmission losses. A strong engineering base enables the
Company to undertake turnkey delivery of electric substances up to
400 kV level series compensation systems (for increasing power
transfer capacity of transmission lines and improving system stability
and voltage regulation), shunt compensation systems (for power factor
and voltage improvement) and HVDC systems (for economic transfer of
bulk power). BHEL has indigenously developed the state-of the-art
controlled shunt reactor (for reactive power management on long
transmission lines). Presently a 400 kV Facts (Flexible AC Transmission
System) project under execution.
 TRANSPORTATION: A high percentage of trains operated by Indian
Railways are equipped with BHEL’s Traction and traction control
equipment including the metro at Calcutta. The company supplies
broad gauge electrical locomotives to Indian Railways and diesel
shunting locomotives to various industries.5000/6000 hp AC/DC
locomotives developed and Manufactured by BHEL have been leased to
Indian Railways. Battery powered road vehicles are also manufactured
by the company.
 INTERNATIONAL OPERARATIONS: BHEL’s products, services and
projects have been exported to over 50 countries ranging from United
States in the west to New Zealand in Far East. The cumulative capacity
of power generating equipment supplied by BHEL outside India is over
3000MW. The Company’s overseas presence includes projects in
various countries. A few notable ones are: 150 MW (ISOI) gas turbine to
Germany, utility boilers and open cycle gas turbine plants to Malaysia,
Tripoli-west, and power station in Libya executed on turnkey basis,
thermal power Plant equipment to Malta and Cyprus, Hydro generators
to New Zealand and hydro power Plant equipment to Thailand. BHEL
has recently executed major gas based power projects in Saudi Arabia
and Oman, a Boiler contract in Egypt and several Transformer contracts
in Malaysia and Greece.
 RENEWABLE ENERGY: Technologies offered by BHEL for non-
conventional and renewable sources of Energy include: wind electric
11
 generators, solar photovoltaic system, stand alone and grid interactive
solar power plants, solar heating systems, solar lanterns and battery
powered road vehicles. The company has taken up R&D efforts for
development of multi-junction amorphous solar cells and fuel cells
based systems.
 INDUSTRIES: BHEL is a major contributor of equipment and systems to
industries: cement, sugar, fertilizer, refineries, petrochemicals, paper,
oil and gas, metallurgical and process industries. The company is a
major producer of large-size thyristor devices. It also supplies digital
distributed control system for process industries and control &
instrumentation systems for power plant and industrial application.
The range of system & equipment supplied includes: captive power
plants, cogeneration plants DG power plants, industrial steam turbines,
industrial boilers and auxiliaries. Water heat recovery boilers, gas
turbines, heat exchangers and pressure vessels, centrifugal
Compressors, electrical machines, pumps, valves, seamless steel tubes,
electrostatic Precipitators, fabric filters, reactors, fluidized bed
combustion boilers, chemical recovery boilers and process controls.
The Company is a major producer of large-size thruster devices. It also
supplies digital distributed control systems for process industries, and
control & instrumentation systems for power plant and industrial
applications. BHEL is the only company in India with the capability to
make simulators for power plants, defense and other applications.

VISION, MISSION AND VALUES

VISION
A Global Engineering Enterprise providing solutions for better tomorrow.
MISSION
Providing sustainable business solutions in the fields of Energy, Industry &
Infrastructure.
VALUES
Governance, Respect, Excellence, Loyalty, Integrity, Commitment, Innovation,
Team Work.
12
PRODUCTS OF BHEL
Bhopal

13
 AC MOTORS AND ALTERNATORS: BHEL is a leading AC Machines
manufacturer and in the last four decades have supplied more than
20000 HT & LT A.C. Machines for various applications to Indian as well
as Export market. The applications include Power Plants, Nuclear
Energy, Petrochemicals, Fertilizers, Refineries, Cement & Steel
Industries, Irrigation Projects, Pipelines, etc. The manufacturing plant
in Bhopal was established in technical collaboration with AEI UK.
Commercial production of A.C. Machines commenced in the year 1963.
Technology was upgraded by collaborating with Siemens AG, Germany
from 1980-1990 and subsequently from 1996-2006. Motors are offered
both in standard as well as tailor made designs to meet customer's
specific needs. High performance is achieved through optimum
utilization of the active materials and components. BHEL A.C. Machines
offer high efficiency, exceptional reliability, quick installation and
minimal maintenance costs. Our engineers combine their extensive
experience with state-of-the-art analytical design tools, latest machine
tools, Six Sigma methodology and advanced material development to
deliver the best product.
Installed Capacity: 2250 machines per annum
 TRANSPORTATION EQUIPMENTS: BHEL's involvement in the
transportation sector has been marked with rapid growth. Today over
85% of Indian Railways, one of the largest railway networks in the
world is equipped with traction equipment built by BHEL. The range
includes traction motors, traction generators/alternators,
transformers, sub-station equipment, vacuum circuit breakers,
locomotive bogies, smoothing reactors, exciters, converters, inverters,
choppers and associated control equipment, viz. master controllers,
HSCBs, chopper controllers brake and door equipment, electronic
controls including software based controls extending to rolling stock
and other transport applications. BHEL has manufactured and supplied
large numbers of electric locomotives (upto 5000 hp) to Indian
Railways and Diesel Electric Locomotives ranging from 350 hp to 2600
hp to cement, steel and fertilizer plants, thermal power stations,
coalfields, ports and other medium and large industries. This has
established BHEL as a leading locomotive manufacturer in the country.
Diesel Multiple Units, underground Metro-rail system at Calcutta,
Electric Multiple Unit (EMU) services at Mumbai, Calcutta, Chennai &
Delhi operate on drives and controls supplied by BHEL. BHEL has also
started the supply of equipment for Dual Voltage EMUs with 3 phase
14
 technology. To contain air pollution & to conserve mineral oil
resources, battery powered road vehicles are in operation in various
cities, BHEL is also ready to undertake turnkey execution of LRT, MRTS
& electric trolley bus.
 HYDRO GENERATORS: Hydro generator is a synchronous alternator
driven by a hydraulic turbine. Motor is synchronous motor to drive
pump. BHEL Bhopal is a leading supplier of large, medium & small
hydro generators, motors, bulb generators and related services.
Installed manufacturing capacity: 2500 MW Sophisticated CAD facilities
ISO-9001 certification
 EXCITATION CONTROL EQUIPMENT: Excitation Control equipment
for Hydro, Thermal Nuclear, Naval and Industrial applications.
Excitation control equipment (automatic voltage regulator (AVR) and
static excitation equipment-(SEE) for semi-static, static and brushless
type of excitation system. Complete range of Digital AVR and SEE
available to suit all types of systems and generators added to product
profile in the year 2003. More than 35 years of field experience. More
than 600 AVRs operating satisfactorily at various Hydro, Thermal and
Industrial Power Plants. A number of captive power plant installed in
Sugar, Chemical, Paper and other industries are also equipped with
BHEL make AVRs Total system solutions on offer Retrofitting of old
excitation control system with latest state of art digital systems
Dedicated shop area with modern manufacturing and testing facilities.
 STEAM TURBINES: BHEL has taken its lead role in following fields:
Turbines:
 Design, Manufacturing, Erection, Commissioning and Services of: 30
MW, 120 MW Steam Turbines 236 MW Nuclear Turbines. 15000 SHP
Marine Turbines 210 MW Steam Turbines.
 Supply of Spares and Repairs of above Steam Turbines.
 R & M and Life assessment studies of BHEL & Non BHEL TG sets.
 Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.
 Repair and supply of Spares for Non BHEL TG Sets. Diversified Projects
for IPR and ISRO: Manufacturing of various components.
 OIL RIGS: BHEL is the only manufacturer of complete Land Drilling Rig
in India. BHEL has supplied 84 Land Rigs to M/s ONGCL and M/s OIL
India Ltd. BHEL has proven capability of designing, manufacturing and
15
 commissioning of different type of land rig ranging from E 760, E 1400,
E 2000, E 3000, Mobile Rig, Desert Rig and TBA Rig (Transportable by
air). BHEL built E 3000 Type rig has capability of drilling up to 6 Km to
10 Km depth. BHEL has executed R&U of 20 Nos. BHEL/ Imported Land
Rigs, to tailor made customer specification, to rejuvenate old rigs and
meet growing customer requirement. R&U of 16 more rigs is in
progress Rig Electrics are manufactured and supplied by BHEL Bhopal
Unit.
 TRANSFORMER: A Leading Engineering Enterprise which Supplies
wide Spectrum of Power Transmission Systems/ Solutions from a
single entity. A Leading Transformer Manufacturer Offering wide range
of Transformers. Installed manufacturing capacity: 18000 MVA/Annum
with dustproof facility in critical areas. The capacity is augmented by
another 12000 MVA/Annum with totally dust proof facility. Having
nearly 5 decades or over 35,000 man-years of experience. Dedicated
shop area of over 80000 sq. meters and unique Ultra High Voltage
testing facility.
 SWITCHGEAR: A leading Switchgear Group involved in Design,
manufacturing, installation, commissioning and services of Switchgear.
A wide spectrum of switchgear catering to various applications like
power station auxiliaries, power distribution, process industries, rural
electrification, open cast mines, electric traction and other special
applications. Market leaders in India. Experience of 5 decades
Thousands of various types of breakers working satisfactorily in India
and abroad. Unique distinction of widest range of medium voltage
Switchgear meeting every requirement of the customer in stringent
Indian conditions. Strong R & D infrastructure. Dedicated shop and
design area of over 50,000 sq meters. Regular facilities are updating
with new capital investment. Clear room facility for GIS Strengths:
 Reliable and problem free product
 Proven product in service
 Repeated successful type testing and special testing
 Largest range to suit various application requirements via Power
Stations Distribution, Industrial & Railways.
 100% routine testing as per IS & IEC. Switchgear design fully type
tested as per IEC: 62271

16
  ON LOAD TAP CHANGER: A leading On Load Tap Changer (OLTC)
group involved in Design, manufacturing, commissioning and services
of Tap Changers. Market leaders in India Latest Technology
incorporating high speed resistor switching of OLTC Capacity to supply
500 numbers OLTC. Experience is more than 4 decades. Dedicated shop
area of over 10,000 sq meters complete system for parallel operation of
transformers and remote Tap changer control panel.
 LARGE CURRENT RECTIFIER: Large Current Rectifier SCR Division of
BHEL, Bhopal has been supplying wide range of Large Current Rectifier
Equipment since year 1969. The large current rectifier equipment
provides DC power for electrolytic process of electrochemical,
aluminum & graphite industries. BHEL have so far supplied more than
60 units of about 1600000 Kilowatt rectifiers for caustic soda,
aluminum smelter and graphite furnaces. Some of the special features
of the large Current Silicon Power Rectifier Equipment are listed below:
 Compact and Rugged design
 PLC controlled Rectifier (Hot standby option available)
 HMI for control, annunciation, status display
 Interface with customer SCADA possible
 Operates in both current and power control modes
 High Efficiency
 Accuracy of control + 1%
 Uniform current sharing
 Large safety margins in Design
 Easy maintenance and monitoring
 Single rectifier unit up to 60 KA
 Auto/Rectifier Transformer & IPT
 Transductors – housed in single tank
 Externally mounted on-load tap-changer
 Non magnetic aluminum rectifier structure
 FRP covers to avoid eddy current losses
 Steel shields
 Suitable for tropical conditions
 Choice of cooling
Rectifier equipment comprises an assembly of semiconductor diodes
mounted on heat sinks along with series connected fuse and surge voltage
protection components, all suitably enclosed and a separately mounted
transformer. Additional items, such as interconnections, control cubicles,
17
switchgear, AC/DC measuring system; AC/DC bus bars are included in scope
of supply when required. For large current applications above 25kA,
important advantages are gained by mounting the rectifier assembly in close
association with the transformer known as 'Rectiformer' by combining the
two units into an integral equipment (a) The space requirement is
considerably reduced (d) Both preparatory & erection work at site is
minimized (c) AC. bus bars connections are reduced to minimum.
 CONTROL AND RELAY PANELS: Experience in the field for more than
40 years. More than 15000 panels supplied to major customers in India
and abroad. Capability to develop complete control of protection
schemes for generation and transmission systems to suit customer
requirements. Applications of latest state of the art numerical relays
with communication facility. Design of control of relay boards based on
latest engineering practices, high degree of reliability and aesthetic
consideration.
 MAINTENANCE OF THERMAL POWER STATION: BHEL is the largest
producer of power generating equipment including turbines,
generators, boilers and auxiliaries in the country. BHEL has already
supplied thermal sets upto 500 MW rating and has the technology to go
upto 800 MW. BHEL manufactured 500/236 MW Nuclear sets are also
installed in the country. The BHEL manufactured sets accounts for 65%
of total installed capacity in India. There is ample scope for improving
the plant availability by cutting down the shut down period, by
Renovation & modernization, rehabilitation and by timely arranging the
spare parts and other services. Based on our more than 35 years
experience in the field of Design, manufacturing, erection and operating
experience, services in steam turbine, BHEL is undertaking renovation
and modernization of BHEL & NON-BHEL Thermal Power Plants. This
includes, Life assessment studies recommendation for up-rating / up-
gradation, also includes retrofitting, repairs, overhauling, with
improved efficiency and heat rate and performance guarantee for a
reasonable time period. Spares for TG sets: For preventive and capital
maintenance, these can be planned in advance, but it is difficult to
predict and to organize the same in case of sudden break-down
especially in case of non-BHEL sets due to various constraints. BHEL
has taken lead role by providing specialized services, retrofitting
renovating and supply of even such spare parts for which complete

18
 design information and manufacturing drawings are not available from
original suppliers.
 FABRICATION: 483 strong workforces of engineers, supervisors and
highly skilled artisans; which include about 200 qualified welders and
welding operators. 20,000 tons of diversified fabrication capability.
More than 40 years experience in fabrication & welding. Total
Engineering solutions & consultancy services for all kinds of fabrication
and welding problems. Accredited with ASME ‘U’ stamp by American
National Boiler Board to manufacture Heat Exchanger and Pressure
Vessels since 1989. All systems qualified and maintained to ISO 9001
and ISO14001 standards. Fully developed ancillary industries within
2kms distance to meet any emergency requirements.

19
 POWER TRANSFORMER
MANUFACTURING
INTRODUCTION
A Transformer is static device used for transforming power from one circuit
to another without changing frequency. The range of power transformers in
B.H.E.L. covers from low voltage medium power transformer to extra large
power transformer of 1500 MVA bank in 765 kV class & HVDC converter
transformers of 1500 MVA banks in ± 500 kV DC . Product range also
includes Shunt Reactor upto 150 MVAR in 400 kV class and 330 MVAR in 765
kV class.

Power transformers have been grouped into three segments based on size
ranges. These three segments are:
 Small power transformers 500 to 7500 kVA
 Medium power transformers 7500 to 100 MVA
 Large power transformers 100 MVA and above.

20
21
STAGES OF POWER TRANSFORMERS MANUFACTURING:
 Design & Drawing
 Winding Manufacturing
 Core Building
 Unlacing of Core
 Fitting Bottom Insulation
 Core Coil Assembly
 Fitting of Top Insulation
 Relacing of Core
 Terminal Gear Mounting
 Final Tanking
 Testing
 Despatch

MAIN PARTS OF TRANSFORMER

CHEESE CORE: It is a part of a reactor.
 Cleaning of Mould:
 Ensure all old cast slush is removed including those on bottom base.
 ‘O’ grade sand paper or cotton can be used for cleaning. If required
while spirit/ trichloethylene may also be used. Adjust any level
difference b/w bottom of mould and centre part.
 Applying Releasing Agent on Mould Surface: All cast surfaces of the mould
shall be covered an even layer of silicon releasing agent.
 Reinforcement with Fiber Glass Chopped Strand Mat: Place fiber glass
chopped strand mat in mould according to drawing.
 Stacking of Cheese Lamination:
 Cheese lamination packets are placed around the circumference in the
form of rings.
 The lamination shall be well wedged. Knife test to be done at 4 different
places.
 Ensure complete section assembly have a smooth surface.
 Maximum deviation b/w different lamination or rings shall be less than
0.6 mm.
 CRGO- Cold Rolled Grain Oriented Silicon Steel (available only in US or
Japan)

22
CORE: BHEL make transformers having Core type configuration. Core is built
up from cold rolled grain oriented silicon alloy steel of the best magnetic
properties. Purpose of using CRGO is to reduce the hysteresis losses.
Laminations of these sheets minimize eddy current losses. CNC machine is
used for slitting; cropping / mitering operations with perfect control un burr
level. A computer program determines number of steps, position of the oil
ducts and the sizes of the laminations for optimum cross section of core and
yokes. In order to achieve a further reduction of iron loss laminations are
mitered and core bolts for clamping are kept to a minimum. Bolts in core legs
are completely eliminated by using resin bonded glass tape for binding or by
using skin stressed cylinder.
 Magnetic circuits are of generally 3 limb construction in single phase
transformer in which only center limb is wound and the outer limbs
provide return path for main flux.
 In three phase transformer 5 limb construction is used which has 2
vertical return limbs and 3 main cores.
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
the secondary 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 broadly classed as:
 Single-phase three-limbed core
 Single-phase two-limbed core
 Three-phase three-limb core
 Three-phase five-limbed core

23
 Stepped core construction

(a) Single-Phase Three-limbed Core:

The windings are placed around the central limb, also known as main limb.
The main magnetic flux generated in the central limb gets divided into two
parallel return paths provided by the yokes and auxiliary limbs. For the same
magnetic flux density as that in the main limb, the auxiliary limbs and the
yokes need to have the cross section only half of the main limb. This type of
transformer core is generally preferred for single-phase transformer, as this
is more economical than two limbed construction discussed below

24
(b) Single-Phase Two-Limbed Core:
Sometimes the single-phase power ratings of transformers are so large that
if the windings of full power ratings were to be placed on the central limb, its
width would become too large to be transported. To mitigate such difficulties
the windings are split into two parts and placed around two separate limbs.
Here the cross-sectional area of the legs (limbs) and the yokes are identical.
Consequently these cores are bulkier than the single phase three-limbed
arrangements. Also the percentage leakage reactance for this type of core
construction is comparatively higher due to distributed nature of the
windings in the two limbs separately.

(c) Three-Phase Three-Limbed Cores:

This type of core is generally used for three-phase power transformer of
small and medium power ratings. Each phase of the winding is placed
around one leg. For each phase of magnetic flux appearing in a limb, the
yokes and the remaining two limbs provide the return path. If the phase
fluxes are denoted as ØA, ØB, ØC, their summation at any instant of time is
identically zero, which can be mathematically stated as ØA + ØB + ØC = 0. In
this type of construction, all the legs and the yokes have identical cross
section.

25
(d) Three-Phase Five-Limbed Cores:
For large rating power transformers, cores have to be built in large
diameters. In case of three phase three-limbed cores, the yokes have the
same diameter as the limbs. In case of large diameter cores, the overall core
height will go up leading to transport problem. For such cases the yoke
cross-sections (and consequently yoke heights) are reduced by
approximately 40% or more and auxiliary paths for the magnetic flux are
provided through auxiliary yokes and limbs. The cross-section and the height
of the auxiliary yokes and limbs are lower than that of the main yokes.

26
CORE MANUFACTURING PROCESS

CRGO (Cold Rolled Grain Oriented) Imported from:

 Nippon Steel Corporation, Yawata Works (Japan)
 VIZ-Steel Ltd., Yekaterinburg (Russia)
 POSCO
Slitting Machine (Sequence of Operation):
 Drawing / Q plan
 Size / Grade CRGO
 Burr Level 20 micron
 Steel width within tolerance
 Every 500m width check Burr Gauge
 Scrap and Buckling
Cropping Machine (Sequence of Operation):
 Revised drawing / QA Plan checked
 Every 100 sheet parameter check

27
After completion of assembly of core including curing of resin glass tape, 10
KV AC test between:
 Core and End-Frame
 Core and Yoke-Bolts
 End-Frame and Yoke-Bolts

FLOW CHART FOR CORE FORMATION

WINDING
Windings form the electrical circuit of a transformer. Their construction
should ensure safety under normal and faulty conditions. The windings must
be electrically and mechanically strong to withstand both over-voltages
under transient surges, mechanical stress during short circuit and should not
attain temperatures beyond the limit under rated and overload conditions.
For core-type transformers, the windings are cylindrical, and are arranged
concentrically. Circular coils offer the greatest resistance to the radial
component of electromagnetic forces, since this is the shape which any coil
will tend to assume under short circuit stresses.

28
WINDING CONDUCTOR
The shape of the winding conductor in power transformers is usually
rectangular in order to utilize the available space effectively. Even in smaller
transformers for distribution purposes where the necessary conductor cross
section easily can be obtained by means of a small circular wire, this wire is
often flattened on two sides to increase the space factor in the core window.
With increasing conductor area, the conductor must be divided into two or
more parallel conductor elements in order to reduce the eddy current losses
in the winding and ease the winding work. Strands may be insulated either
by paper lapping or by an enamel lacquer. The matter is mechanically soft. In
order to withstand the short circuit forces it is sometimes necessary to
increase the strength of the material by means of a cold working.
In large power transformers the mechanical forces during short circuit
current have often more influence on the winding dimensions then thermal
aspects and loss considerations.
Generally two types of conductors are used for winding.

PAPER INSULATED COPPER CONDUCTOR (PICC)

In PICCs the strands (Copper conductors) have a lapping of paper insulation.
The paper lapping is built up of thin paper strips, a few centimeters wide,
wound around and along the strand as indicated in figure. The paper is
lapped in several layers to obtain the necessary total thickness set by the
electrical and mechanical stresses.

29
CONTINUOUSLY TRANSPOSED COPPER CONDUCTOR
Special kind of winding conductor is the ‘Continuously Transposed Cable
(CTC)’. This cable is built up of two layers of enamel lacquer insulated
strands arranged axially upon each other as shown in figure. By transposing
the outer strain of one layer to the next layer with a regular pitch and
applying common outer insulation a continuous transposed cable is
achieved. When traversing the same flux for a whole transposition cycle, all
strands loops receive the same induced voltage, and circulating currents
between the strands are avoided.
Transposition of strands must also be made in windings with conventional
conductors to avoid circulating currents. If necessary for increased
mechanical strength, the strands are covered with the epoxy glue, which
cures during processing the winding. For lower voltages netting around the
transposed cable is used to keep the strands together. For higher voltages
insulation paper covers the cable.

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
ducts between turns. Spiral coils are normally wound on a Bakelite or
pressboard cylinder. 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.

30
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 or double layer or multi-
layer, if the number of turns is 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 equalize the impedances of the parallel conductors.

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 withstands behavior of disc coils can be increased
if the turns are interleaved in such a fashion that two adjacent conductors
belong to two different turns. Figure 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 in the number

31
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.

1. Disk type
2. Large no. of turns
High Winding Voltage 3. Low current density
4. Comparatively small conductor cross
section
5. Connected to Core
1. Single layer helical type
2. Less no. of turns
Low Winding Voltage 3. High current density
4. Large conductor cross section
5. Nearest to the core
1. Interleaved helical type
2. Generally connected in series with
Tap Winding high voltage
3. Winding
4. Various coils are provided for tapings
to regulate voltage to +/-10% or more

32
PROCESSING OF WINDINGS

33
CORE AND COIL ASSEMBLY
A part of the transformer manufacturing process, the core and coil assembly
aspect plays a significant role where the core assembly is vertically placed
where the foot plate touches the ground and the top yoke is removed. The
limbs of the core are tightly wrapped with cotton tape and then varnished
during the manufacturing and even repairing process.
 First, the individual windings are assembled one over the other to form
the entire phase assembly.
 The radial gaps between the windings are subdivided by means of solid
transformer board barriers.
34
  Stress rings and angle rings are placed on top and bottom of the
windings to achieve a contoured end insulation design for optimal
control of the oil gaps and creep age stresses.
 The complete phase assemblies are then carefully lowered over the
separate core legs and solidly packed towards the core to assure
optimal short circuit capability.
 The top core yoke is then repacked and the complete core and coil
assembly is clamped.
 The lead exits (if applicable) and the lead supports and beams are
installed. All winding connections and tap lead connections to the tap
changers are made before drying the complete core and coil assembly
in the vapor phase oven.

PROCESSING OF CORE AND COIL ASSEMBLY

The completed core and coil assembly is thoroughly dried to pre-determined
power factor readings by the vapor phase drying process, providing the
fastest, most efficient and most effective drying of the transformer insulation
available. The vapor phase process uses the standard kerosene cycle method.
In this system, kerosene is vaporized and drawn by vacuum into a heated
autoclave where the transformer has been placed. Condensation of the vapor
on the core and coil assembly rapidly causes the temperature to rise and
allows moisture to be drawn out of the insulation by the vacuum. High
temperature and pressure are used to accelerate the drying process.
When the power factor measurements and the removal rate of moisture have
reached the required levels, the flow of kerosene vapor is stopped and a high
vacuum is used to boil off the remaining moisture and kerosene. Because so
much water is removed in this process, the insulation physically shrinks in
size. Following removal from the autoclave, the transformer is repacked as
required and then undergoes its final hydraulic clamping to ensure
maximum short-circuit strength in the finished product.

DRYING OUT PROCESS

In order to ensure power supply is completely reliable it depends on high
performance transformers and in order to achieve that the drying out
process is extremely important. Under this process, the paper insulation and
pressboard material, which make up a significant proportion by volume of
transformer winding, have the capacity to absorb large amounts of moisture
35
from atmosphere. The presence of this moisture brings about the reduction
in the dielectric strength of the material and also an increase in its noise.

TANK FABRICATION AND FITTINGS

The tanks are made of high quality steel and can withstand vacuum and
pressure test as specified in IS as well as by the customers. All welds are
checked ensuring 100 % leak proof seems and mechanical strength. All tanks
are pressure tested before tanking the active part. The Pressed steel
radiators are used to dissipate heat generated at rated load. The fin height
and length are calculated according to the rating of transformers as well as
customers' specifications. The fins can be plain or embossed. The radiators
are fitted variably according to the rating of transformer. For smaller rating
radiators are directed welded to the main tank while for higher rating
detachable type radiators are provided with valves to facilitate during
transportation and handling at site. The tanks are fabricated from MS plates
and are welded construction. They are tested at a pressure of 0.35 Kg. /Sq.
cm. for oil leakage output and they are normally welded directly to the tank.
However, transformers can be supplied with detachable radiators.
INSULATION SHOP: Insulating materials used for the transformer
protection is given below:
Sr. No. Material Applications
1. Transformer Oil Liquid dielectric and coolant
(Mineral Oil, PXE)
2. Craft Paper 1. Layer winding insulation
2. Covering copper conductor & transposed
copper conductor
3. Creep Kraft paper Insulation of winding lead and shield
4. Press Paper Backing paper for axial cooling duct
5. Press Board Angle ring cap, lead out, insulating end of winding,
cylinder, barrier, washer, yoke, top and bottom coil
clamping ring
6. Wood and laminated Cleat, core/yoke clamp, wedge block
wood
7. Insulation Tap Tapping and bending of transformer cores
8. Phenolic laminated Terminal gear support and cleat, gap filter in reactor,
paper based sheet tap changer components
9. Phenolic laminated Terminal board, for making core duct, support and
cotton fabric sheet cleat

36
EQUIPMENTS USED FOR THE PROTECTION OF POWER
TRANSFORMER
 Lightening Arrester
 Over Current Relay
 Buccholz Relay
 Earth Fault Relay
 Oil Level Indicator
 Over Fluxing Relay

HIGH VOLTAGE DIRECT CURRENT TRANSFORMER (HVDC)

Electric power transmission system uses direct current for the bulk
transmission of electrical power. HVDC uses voltages b/w 100 kV and 1500
kV. It is also called converter transformer. It converts AC to DC because
losses in DC are less as compared to AC. HVDC is used as an alternative to AC
for transmitting electrical energy over long distances or b/w AC power
systems of different frequencies.

TESTS ON TRANSFORMER
The following tests are generally performed on the transformer.
R-Routine Tests: Tests are required for each individual transformer.
 Measurement of winding resistance
 Measurement of voltage ratio, polarizer, voltage group, magnetic
current
 Measurement of no load loss, core loss, open circuit test and no load
current
 Separate source voltage withstand test
 Switching in pulse voltage withstand test
 Full wave/chopped wave lighting impulse voltage withstand test
 Induced over voltage withstand test (ACSD/ACLD)
 Measurement of winding resistance
 Measurement of load loss and impedance
 OLTC operation
 Measurement of Insulation Resistance
 Repeat no load loss test
 Magnetic circuit (Isolation) test
37
T-Type Tests: Tests are conducted on a transformer which is representative
of other transformers.
 Temperature rise test
 Zero sequence impedance measurement
 Measurement of harmonics in no load current
 Measurement of sound level
 Measurement of capacitance and tan-delta
 Dissolved gas analysis (DGA) of oil filled in the transformer
S-Special Tests: Tests are other than routine & type test as agreed between
customer and manufacturer.
 Measurement of power tanker by cooling circuit
 Withstand test on marshalling box
 Frequency Response Analysis (FRA)
 Short Circuit Test
M-Mechanical Tests:
 Vacuum test on transformer tank
 Oil pressure test on completely assembled transformer

38
 BUSHING
MANUFACTURING

39
INTRODUCTION
In electrical power, a bushing is an insulated device that allows an electrical
conductor to pass safely through a (usually) earthed conducting barrier such
as the wall of a transformer or a circuit breaker. In its simplest form, a
bushing consists of a central conductor embedded in a cylindrical insulation
material having a radial thickness enough to withstand the high voltage.
A bushing has to:
 Carry the full load current.
 Provide electrical insulation to the conductor for working voltage and
for various over - voltages that occur during service.
 Provide support against various mechanical forces.
 Acts as an external safety device.

CLASSIFICATION OF BUSHINGS
Bushings are classified according to the following factors:
 APPLICATION OR UTILITY
 ALTERNATOR BUSHING: AC generators require bushings up to 33 kV,
but 22 kV, is more usual. With modern alternators, current ratings up to
20,000 Amp are required.
 BUSHINGS FOR SWITCHGEAR: In the switchgear, bushings are to
carry the conductors through the tank wall, and support the switch
contacts.
 TRANSFORMER BUSHINGS: Transformers require terminal bushings
for both primary and secondary windings. In some cases, a high voltage
cable is directly connected to the transformer via an oil filled cable box.
A bushing then provides the connection between the cable box and
transformer winding.
 WALL OR ROOF BUSHING: In recent years, many sub-stations for 132
kV and above, in unfavorable situations have been put inside a building.
For such applications wall/roof bushings are used.
 LOCO BUSHINGS: These bushings are used in freight loco and AC EMU
transformers for the traction application.
 NON-CONDENSER AND CONDENSER BUSHINGS
 NON-CONDENSER BUSHING: In its simplest form, a bushing would be
a cylinder of insulating material, porcelain, glass resin, etc. with the
40
 radial clearance and axial clearance to suit the electric strengths. The
voltage is not distributed evenly through the material, or along its
length. As the rated voltage increases, the dimensions required become
so large that this form of bushing is not a practical proposition. The
concentration of stress in the insulation and on its surface may give rise
to partial discharge. This type of bushing is commonly used as low
voltage bushings for large generator transformers.
 CONDENSER BUSHING: The condenser bushings are made by inserting
very fine layers of metallic foil into the paper during the winding
process. The inserted conductive foils produce a capacitive effect which
dissipates the electrical energy more evenly through the insulated
paper and reduces the electrical field stress between the energized
conductor and any earthed material.

BUSHING DESIGN
All materials carrying an electric charge generate an electric field. When an
energized conductor is near any material at earth potential it can cause very
high field strengths to be formed. As the strength of the electric field
increases, leakage paths may develop within the insulation. If the energy of
the leakage path overcomes the dielectric strength of the insulation, it may
puncture the insulation and allow the leakage current to flow through the
shortest path through the earthed material toward the earth causing burning
and arcing. The design of bushing must involve following considerations:
 AIR-END CLEARANCE: The air-end clearance has to be sufficient to
meet the specified overvoltage tests. It is also determined by the creep
age distance, and the proportion of it that is protected from the rain.
Having determined the air-end length, the air-end dimension of the
internal condenser can be determined. It is not necessary to grade
100%. Internal grading of 70% or less will give adequate surface
grading for large bushings.
 OIL-END CLEARANCE: As internal breakdown unlike air flashover, is
more severe, specifications, therefore, demand an internal breakdown
with a sufficient margin (about 15%) above the air withstand value.
Both power frequency, and impulse voltage withstand tests have been
used to specify this characteristic.
 NUMBER OF CONDENSER LAYERS: The number of partial condensers
is so chosen that the test voltage of each partial condenser should be
between 10 kV to 15 kV. If more foils are introduced, it will cause too
41
 many folds and weaken the bushing. Also, will be air introduced in the
folds, complicating the manufacture of bushing of high voltage class.
 LENGTH OF EARTH LAYER: The length of the earth layer of a bushing
is usually determined by the accommodation required for current-
transformers, or by mounting considerations, though in some cases it
may be allowed to assume its optimum dimension in relation to the
radial dimensions. The ratio of Length of first foil (L1) and Length of
nth foil (Ln) may be taken between 3 and 4. This ratio is denoted by a.
 RADIAL GRADIENTS AND DIAMETERS: The radial gradient is limited
for avoiding damage by discharges at the power-frequency test
voltages, whether one minute or instantaneous. If the ratio of the earth
layer diameter to that of the conductor 𝑟𝑛 𝑟𝑜 ⁄ is denoted by 𝛽, the
stresses at the HV end and the earth voltage end will be equal, if the
product of 𝛼and 𝛽is unity. However, it is not always possible to achieve
this value. Hence 𝛼and 𝛽can vary from 0.8 to 1.2 if 𝛼, 𝛽=1, then Ln.Dn =
L1.D0
 EQUIPOTENTIAL LAYER POSITION: After determining the dimensions
of the inner and outer layers of the condenser, the position of the other
layers can be calculate. The basis of the design of the condenser bushing
is generally equal partial capacitances, which mean equal voltage on
them and equal axial spacing between the ends of layers.

INSULATING MATERIAL
PORCELAIN INSULATION:
A basic porcelain bushing is a hollow porcelain shape that fits through a hole
in a wall or metal case, allowing a conductor to pass through its center, and
connect at both ends to the other equipments. The inside of these bushings is
often filled with oil to provide additional insulation and used up to 36 kV.
PAPER INSULATION:
The insulating material of bushing windings is usually paper-based with the
following most common types:
 SYNTHETIC RESIN BONDED PAPER (SRBP): In SRBP bushings, one side
of the paper is film coated with synthetic resin which is cylindrically
wound under heat and pressure inserting conducting layers at
appropriate intervals. However, use of SRBP bushings is limited to
voltages around 72.5 kV. There is also the danger of thermal instability
of insulation produced by the dielectric loss of the resins. The SRBP
42
 insulation is essentially a laminate of resin and paper which is prone to
cracking. Moreover, paper itself will include air which will cause partial
discharges even at low levels of electrical stress.
 OIL IMPREGNATED PAPER (OIP): OIP insulation is widely used in
bushing and instrument transformers up to the highest service
voltages. In the manufacturing process, the Kraft paper tape or sheet is
wound onto the conductor. Aluminum layers are inserted in
predetermined positions to build up a stress - controlling condenser
insulator. The condenser layer may be closer together, allowing higher
radial stress to be used. The bushing is fully assembled before being
vacuum impregnated in order to contain the oil.
 RESIN IMPREGNATED PAPER (RIP): RIP bushings are wound in a
similar manner as OIP. The raw paper insulation is then kept in a
casting tool inside an auto-clave. A strictly controlled process of heat
and vacuum is used to dry the paper prior to impregnation with epoxy
resin.

CONSTRUCTIONAL DETAILS AND MAIN PARTS OF BUSHING

CORE:
The core of bushing consists of a hollow or solid metallic tube, over which
high grade electrical Kraft paper is wound. For condenser cores, conducting
layers of metallic foil are introduced at predetermined diameters to make
uniform distribution of electrical stress. The winding of the condenser core is
done in a dust-free chamber. The core is then processed; this comprises of
drying in a high degree of vacuum (0.005mm), and then impregnating with
high quality, filtered and de-gassed transformer oil.
PORCELAIN:
Bushings for outdoor applications are fitted with hollow porcelain insulators.
The OIP bushings are provide with insulators, both at air and oil ends, thus
forming an insulating envelope, and the intervening space may be filled with
an insulating liquid or another insulating medium. The function of an
insulator is to resist flash over in adverse conditions. This is determined by:
 The profile of the dielectric.
 The mounting arrangement of the insulator, i.e., vertical, horizontal, or
inclined.
 The properties of the surface, i.e., hydrophobic nature, toughness etc.

43
TOP CAP:
This is a metallic housing for the spring pack. It serves as an in-built oil
conservator to cater for oil expansion, and has an oil level indicator. In many
cases, it also serves the purpose of a corona shield.
MOUNTING FLANGE:
This is used for mounting the bushing on an earth barrier, such as a
transformer tank or a wall. It may have the provisions for following:
 CT accommodation length
 Rating plate giving the rating and identification details of bushing.
 Test tap
 Oil drain plug for sampling of oil
 Air release plug
The design of the flange and top cap is such as to minimize the loss due to
hysteresis and eddy current effects. When heavy currents are being carried,
this loss raises the temperature of the flange and top cap to a noticeable
extent. For heavy currents, ordinary cast iron material cannot be used; hence
non-magnetic materials such as stainless steel or aluminum are used.
TEST TAP:
The test tap is provided for measurement of the power factor and
capacitance of the bushing during testing and service. The test tap is
connected via a tapping lead to the last condenser foil of the core within the
bushing. During normal service, this tapping is electrically connected to the
mounting flange through a self-grounding arrangement.

44
 REFERENCES
 www.wikipedia.org
 www.electrical4u.com
 www.bhelbhopal.co.in
 Daily Report Diary.
 Electrical Machines by P.S. Bimbhra
 Power System by J.B. Gupta and Power System by V.K. Mehta
 Electric Machines by Ashfaq Husain

45