( HUMAN RESOURSE DEVELOPMENT CENTER )

A TRAINING REPORT ON (TRANSFORMER)

SUBMITTED TO

B.H.E.L
( BHARAT HEAVY ELECTRICAL LIMITED )

IN PARTIAL FULFILLMENT OF REQUIREMENT FOR THE

DEGREE OF BACHELOR OF TECHNOLOGY

(ELECTRICAL ENGINEERING )

SUBMITTED BY- UNDER THE GUIDENCE OF

VISHNU SHRI SUDHIR KUMAR SHUKLA

(ELECTRICAL ENGINEERING ) DY. MGR (PRODN)

RUSTAM JI INSTITUTE OF TECHNOLOGY TEKANPUR

GWALIOR MADHYA PRADESH
 ( HUMAN RESOURSE DEVELOPMENT CENTER )

A TRAINING REPORT ON (TRANSFORMER)

SUBMITTED TO

B.H.E.L
( BHARAT HEAVY ELECTRICAL LIMITED )

DECLARATION
I hereby declare that the work presented in this summer training entitled on
“TRM” is in partial fulfillment for the awarded of degree of bachelor of
Technology in Electrical Engineering. The work has been carried out at
B.H.E.L., Bhopal and is an authentic record of own work.

We hereby declare that above statement is correct to the best of my

knowledge.
BHOPAL- VISHNU

Date:-23/08/2022 TOKEN NO : VTN/2022/00159

 B.H.E.L
( BHARAT HEAVY ELECTRICALS LIMITED )

CERTIFICATE

This is to certify that the work embodied in this project work entitled “TRM”
has been satisfactorily completed by VISHNU. It is a bonafide piece of work,
carried out under the guidance of H.R.D.C. B.H.E.L , BHOPAL by the student
during the period of 02/08/2022 – 23/08/2022 under the guidance of
undersigned. It is further certified that the work reported in the project fulfills
the requirement of the ordinance related to the degree of B.Tech. in Electrical
Engineering RUSTAM JI INSTITUTE OF TECHNOLOGY TEKANPUR
(GWALIOR).

UNDER THE GUIDANCE OF

SHRI SUDHIR KUMAR SHUKLA

DY. MGR (PRODN)

 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to SHRI SUDHIR KUMAR

SHUKLA sir for providing me this golden opportunity to work as trainee in the

highly renowned company “BHARAT HEAVY ELECTRICALS LIMITED”.

I would also like to thank my friends and fellow trainee who contributed to the

useful discussion in the plant. These 3 weeks in BHEL have certainly raised my

knowledge to a new level.

 BHEL BHOPAL OVERVIEW
BHEL is an integrated power plant equipment manufacturer and one of the largest engineering
and manufacturing companies in India in terms of turnover. BHEL was established in 1964,
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.

BHEL is engaged in the design, engineering, manufacture, 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 Defence. They have 15 manufacturing divisions, two repair units, four
regional offices, eight service centres and 15 regional centres and currently operate at more
than 150 project sites across India and abroad. They place strong emphasis on innovation and
creative development of new technologies. Their research and development (R&D) efforts are
aimed not only at improving the performance and efficiency of our existing products, but also
at using state-of-the-art technologies and processes to develop new products. This enables
them to have a strong customer orientation, to be sensitive to their needs and respond quickly
to the changes in the market.
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, Alstom SA, Siemens AG and Mitsubishi Heavy
Industries Ltd., together with technologies developed in our own R&D centres.

BHEL has 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.

They have been exporting their power and industry segment products and services for over 40
years. BHEL’s global references are spread across 75 countries. 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.
.
 PRODUCTS OF BHEL

AC Motors & 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.

Installed Capacity: 1850 machines per annum

HYDRO TURBINES
 • A leading engineering enterprise which supplies all types of equipment for
hydro power generation.
• A leading turbine manufacturer offering a wide range of Hydro Turbine,
Valves, Governors, Turbine and Station Auxiliary systems, Balance of plants
for Hydro Power Station and related Services.
• Installed manufacturing capacity:2500 MW/annum.
• Two units manufacturing hydro turbines.
• In the market for more than three decades.
• Dedicated shop area of over 100000 sq. meters.
• Ultramodern model development and testing facilities.
• Sophisticated CAD/CAM facilities.
• ISO 9001 Certification.
• ASME "Q" stamp for fabrication facilities.

HYDRO GENERATORS

• 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.

HEAT EXCHANGER

Auxiliary Heat Exchangers

Different types of auxiliary heat exchangers are being manufactured at BHEL.
Depending upon application these auxiliary Heat Exchangers are named as
• Air Coolers (CACW)
• Oil Coolers (Shell & tube type / Frame and tube type (Single tube &
Concentric double tube construction) / OFAF), Plug in type
• Water Cooler (Shell & Tube type)
• Hydrogen Cooler (Frame and tube type).
• Air Cooler CACA ( Duct and tube type)
To ensure long life of these coolers materials for different components is decided
carefully considering its application and water chemistry. Construction ally these
coolers are very easy to maintain.
 STEAM TURBINE

Turbines

• Design, Manufacturing, Erection, Commissioning and Services of :

30 MW, 125 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.

TRANSFORMER

• 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 being augmented by another 12000
MVA/Annum with totally dust proof facility
• Having nearly 4 decades or over 30,000 man-years of experience
• Dedicated shop area of over 80000 sq. meters and unique Ultra High Voltage
testing facility

SCOPE OF TRANSFORMER IN BHEL BHOPAL

Power Transformers:
Up to 765kV Class; 500 MVA 3 Phase; 1500 MVA 1 Phase
Bank
Gapped Core Reactors:
Up to 650kV Class; 120 MVAR with Neutral Grounding Reactor
HVDC Transformers & Smoothing Reactors
± 500kV DC Converter Transformers;315 MVA, 3 winding,1
Phase
± 500kV DC Smoothing Reactors; 254 MVAR
Instrument Transformers
Up to 800kV Class
Transformer Bushings
Tap Changers - M&V Type
Radiators and Air/ Water Coolers

PRODUCTS OF TCB
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 of traction substations suitable for Railway
Electrification.
• Surge Capacitor for protection of Rotating Machine and Generator
transformers winding 15 kV and 40 kV, 0.125 micro farad.
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.
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
• Control for protection Panels for substations up to 400 kV, distribution feeders
and capacitors banks.
• OLTC control panels.
• Controls for Nuclear Power Plants

FACILITES

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 facitlity are being augumented 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 minimum
25 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 upto 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 stabilisation
A well equipped insulation shop with facilities like circular saw,
 REFERENCES

Transformer & reactors supplied till March 2012 - 4483 nos totaling 3,10,000 MVA of
various voltage class and ratings
Transformers and Shunt Reactors supplied up to March 2000:
kV Class Type Nos. Supplied MVA
132 Power Transformers and Shunt Reactors. 2259 53228
220 Power Transformers and Shunt Reactors. 915 91663
400 Power Transformers and Shunt Reactors. 600 93527
Total 3766 238418

Supplied to all major utilities in India:

(NTPC)
PGCIL
NJPC
NHPC
NLC
NPCIL
NEEPCO
APTRANSCO
APGENCO
JPPCL
ALL State Electricity Boards (SEBs)

Abroad:
TNB, Malaysia
PPC, Greece
MEW, Oman
OCC, Oman
GECOL, Libya
Trinidad & Tobago
New Zealand
Tanzania etc
 INTRODUCTION OF TRANSFORMER

A transformer, in its simplest form, consists of coils wound around a magnetic

core, linking the flux flowing through this core.

A transformer works on the principles of induction , wherein the energy is transferred

from one electrical circuit to the other through a magnetic circuit. The underlining
principle is that only the current and voltages shall be transformed and energy will
only get ‘transferred’. An ideal transformer may be seen in its equivalent electric
circuit with certain no-load and load losses occurring inside the transformer. In
power system, this may also be seen as a black box having a fixed percentage
impedance.

A transformer is essentially made of materials like copper, cold-rolled grain oriented

(CRGO) steel, insulating oil, pressboard and paper insulation, and other ferrous
and non-ferrous materials. The characteristic of each of these material is vital to
the functioning of transformer.

Windings and Insulation system are the heart of transformer. The size of conductors
used in windings relate to the current flowing therein and the insulation used
depends on the voltage level and the expected impulse characteristics. Besides,
the transient voltage distribution and the internal heat transfer in the windings, are
also critical to the trouble-free operation of transformer. Adequately strong clamping
structures for wound coils, ensure their stability during the axial and radial stresses
developed due to short circuit forces.

Transformer core, which is made of CRGO laminations of different thickness,

depending upon the transportability, operational limitations of flux density in the
core and guaranteed performance parameters for the transformers. Besides, a
solid clamping structure is essential both to lift the core during manufacturing as
well as to keep it in shape during operation.

Due to the systemic change in voltage requirements, voltage regulation is an

important phenomenon in Power Transformers. For this, selection of suitable Tap-
Changing equipment according to the specified range is critical. Also, its control,
both local and remote, are important for its integrated operation with the system.

The protection of the equipment while in service is very important and so the
protection devices / auxiliaries such as Buchholz relay, temperature indicators,
pressure relief valve, bushing, cable box, oil preservation system (Air cell), breathers
etc. Are also important to the operation of transformer.
A good design is only as good as the finished manufactured product so the
manufacturing is vital for proper operation of Transformer. Activities like core
building, preparation of windings, coil assembly, core and winding assembly,
Terminal Gear Assembly, Assembly inside tank, Processing and servicing of
transformer, Tanking etc. are to be carried out with meticulous care and applicable
quality norms. Being hygroscopic material, the insulation inside the transformer
absorbs moisture during manufacturing. This needs to be extracted through
conventional vacuum drying or Vapour phase drying according to applicable
standards.

The testing of transformer verifies the correctness of design and manufacturing.

Through different tests such as Routine and Type testing, specified in national
and International standards such as IS:2026, IEC-60076 etc., the transformer is
checked against stringent operating conditions and its smooth working in the field
is ensured.
WORKING PRINCIPLE OF A TRANSFORMER
A transformer is a static piece of apparatus used for transferring power
from one circuit to another without change in frequency. It can raise 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 physical basis of a transformer is mutual inductance between two circuits

linked by a common magnetic flux through a path of low reluctance as shown in
fig. 1

The two coils possess high mutual inductance. If one coil is connected to a
source of alternating voltage, an alternating flux is set up in the laminated core,
most of which is linked up with the other coil in which it produces mutually induced
emf (electromotive force) according to Faraday's 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 (entirely magnetically) from the first coil (primary winding) to the second
coil (secondary winding).

Figure 1. Diagram showing magnetic circuit and windings of a transformer.

 LOSSES IN TRANSFORMERS

Losses in transformers are

No-Load Losses-

It includes both hysteresis loss and eddy current loss. As the core flux in a
transformer remains practically constant at all loads, the core-loss is also constant
at all loads.

Hysteresis loss, Wh = Khf Bm1.6 watts

Eddy current loss, We = Kef2Kf2 Bm2 watts

Where,

Kh = the hysteresis constant

Ke = the eddy current constant
Kf = the form factor

These losses are minimized by using steel of high silicon content for the
core and by using very thin laminations. The input power of a transformer, when
on no-load, measures the core-loss.

Load Losses-

This loss is mainly due to the ohmic resistance of the transformer winding.
Copper-loss also includes the stray loss occurring in the mechanical structure
and widening conductor due to the stray fluxes. Copper-loss (I2R-loss plus stray
loss) is measured by the short-circuit test.
THREE-WINDING TRANSFORMER

Purpose

A transformer may have additional windings apart from the two conventional
main windings depending upon the particular application and type of connection
(of the main windings). In three-winding transformers, the third winding is normally
called as tertiary winding and it is provided to meet one or more of the following
requirements:

(a) For an additional load which for some reason must be kept isolated
from that of secondary.
(b) To supply phase-compensating devices, such as condensers,
operated at some voltage not equal to primary or secondary or with
some different connection (e.g. mesh).
(c) In star/star-connected transformers, to allow sufficient earth fault
current (zero-sequence component current) to flow for operation of
protective gear, to suppress harmonic voltages and to limit voltage
unbalance when the main load is asymmetrical, the tertiary winding
is delta-connected.

(d) As a voltage coil in a testing transformer.

(e) To load charge split winding generators.
(f) To inter-connect three supply systems operating at different voltages.
 CORE

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

(a)Single-phase three-limbed core

(b)Single-phase two-limbed core
(c)Three-phase three-limbed core
(d)Three-phase five-limbed core.

Figure-1 (a) Single-phase three-limbed core.

(1) main limb (2) Top yoke (3) Bottom yoke (4) Aux. limb

Figure 1 (b) Single-phase two-limbed core. (1) Main limb (2) Top yoke (3)
Bottom yoke
 Figure 2 Three-phase three-limbed core: (1) main limbs, (2) top yokes, (3) bottom
yoke.

Figure 3. Three-phase five limbed core: (1) main limbs, (2) top main yokes, (3)
bottom main yokes,(4) auxiliary top yokes, (5) auxiliary bottom yokes, (6) auxiliary
limbs.

CORE CONSTRUCTION
Some of the very early transformer cores were made of inferior grades of
laminated steels which had inherently higher core losses and showed pronounced
ageing effects, further aggravating the hysteresis component of iron-losses in the
equipment. It was subsequently found that very small quantities of silicon alloyed
with low carbon content steel produced a material with low hysteresis losses and
high permeability. These steel sheets alloyed with silicon mitigated the problem of
ageing and improved the permeability and consequently reducing the magnetizing
current and core losses. In the ever increasing pursuit of increasing the power
ratings and reduction of core-losses, another innovative technique from steel
manufacturers came in the form of cold rolling with orientation of the grain in the
direction of rolling. This core steel known as CRGOS (cold rolled grain oriented
silicon steel) has the minimum epstein losses to the flow of magnetic flux along
the directions of grain orientation and this material is universally used for the
manufacture of transformer cores.
The adoption of CRGOS has brought about considerable reduction in the
specific iron-losses (W/kg.) over the earlier grades of core steel. However, CRGOS
is susceptible to increased losses due to flux flow in directions other than that of
grain orientation, effect of mechanical strain due to clamping pressure, bolt holes,
jointing of limb with yokes, etc. Apart from this sensitivity to the direction of rolling,
CRGOS sheets are also very susceptible to impaired performance due to impact
of bending, blanking the cutting. Both surfaces of the core steel sheets are provided
with an insulating of oxide coating (commercially known as Carlite). The stacking
factor of lamination improves by using thicker laminations, but eddy current loss
goes up in proportion to square of the thickness of the lamination. For reducing
the eddy current losses, thinner laminations are preferable even though the stacking
factor goes down. Deburring of the laminations improves the stacking factor and
minimizes the eddy losses. After machining, the material has to be annealed

CORE ASSEMBLY

Core building from the finished lamination sheets is done in horizontal

position on specially raised platforms. The lamination sheets are susceptible to
mechanical stresses of bending, twisting, impact, etc. A lot of care is exercised
while handling and normally two persons are needed to hold the two ends of the
laminations at the time of laying.
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 position as 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 overlapping 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
securedthrough bolts and steel bands at a number of positions.
The platform on which the core building takes place is of special design
and the core-end frame assembly can be raised to the vertical position alongwith
the platform which serves as a cradle. Subsequently the platform is disengaged.
In this process, the core assembly is spared from the mechanical strain of lifting
and raising in the vertical position. Small-size cores can however be built up without
these special platforms.
Steel bands used for tightening the laminations is only a temporary
arrangement and are later removed, otherwise these will form short circuited turns.
Two commonly used methods of holding the leg laminations together is their
clamping by either (a) resiglass tape or (b) using skin stressed bakelite cylinders.
In case of resiglass tapes, these are tightly wound around the legs at specified
pitch and cured by heating. The tape shrinks after heating and provides a firm
grip. The tensile strength of resiglass tapes is even higher than that of steel tapes.
In the case of core legs tightened by skin stressed cylinders (base cylinder of
innermost coil), these are lowered from the top and the steel bands and cut
progressively. Wooden wedges are inserted along the packet corners and
hammered down, so that the enveloping bakelite cylinder and the leg laminations
are fitting tightly against each other.
Conventionally, the core is assembled along with all the yokes, and after
assembly the top yokes are unlaced after removing the top-end frames for the
purpose of lowering the windings. This takes a lot of labour and manufacturing
time. The latest development is to assemble the core without top yokes and insert
the top yokes after lowering all the windings in the core leg.

CORE BUILDING
The core forms the magnetic circuit of the transformer. Core is built up from
cold rolled grain oriented, silicon alloy sheet steel of the best magnetic properties.
The material is either received in rolled coil form or in finished sizes of core sheets,
ready for core building. When the material is received in coil form, it is slitted,
cropped and mitred to the required dimensions based on the design requirements.
CNC machines are now available which can perform the above operations with
perfect control on burrs. The size, type, and construction of the core, like the
number of steps, number of limbs, height, etc. depend on the number of phases
and the size of the transformer.

The sequence of operations for core building and assembly are as under:
(a).Slitting of core steel rolls to required width on slitting machines.
(b).Cropping and mitring to the required dimensions.

(c).Hole punching in the laminations where required.

(d).Stacking of laminations of different size to the required thickness.
 LAMINATIONS OF CORE

Windings
MATERIALS USED IN WINDING
1.PICC-Paper Insulated Copper Conductor
2.CTC-Continuously Transposed Copper
3.BPICC-Bunched Paper Insulated Copper
4.Glued CTC
TYPES OF WINDINGS
The choice of the type of windings is largely determined by the rating of the
winding. Some of the common types of windings are described below.

Distributed Cross-over Windings

These windings are suitable for currents not exceeding about 20A. They
comprise wires 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
 Figure 1. Cross-over Coils

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
(Fig. 2)
 Figure -2 Disc Winding
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)
+

Figure 3 Spiral coil (edge wound)

Spiral windings may be made as single layer or multilayer type. Figure 4
shows a double-layer spiral coil where an oil duct separates the two 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.
 Figure 4. Spiral coil (double layer)

Normally it is not necessary to provide any transposition between the parallel

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

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
conducors which equalise the impedances of the parallel conductors

Figure 5. Helical coil (Single layer) Figure 6, Helical coil(double layer)

CONTINUOUS DISC WINDNG
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 good withstand of axial
forces. Another particular advantage of these coils is that, each section can have
either integral or fractional number of turns.

Figure 7 Continuous disc winding.

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

Figure 8. Transpositions in helical winding (a) Complete transposition (b) and (c)
Partial transposition(b) With a multi-start helical winding, the transposition can be
achieved by using rotary transposition. Figure 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.

Figure 9. Rotary transposition for double-start helial windng

(c) For the disc winding having more than one conductor in a parallel transposition

is made between the conductors by changing their mutual position at each cross-
over from one section to another (Fig. 10)

Figure 10. Transposition at each cross-over in continuous disc winding.

Interleaving 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 two adjacent conductors belong to two different
turns. Figure 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
havnd for winding when n in 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.
 Figure 11. Interleaved disc winding (2 discs per group)

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

more number of discs (say four) in each interleaved group .
This gives further improved behaviour against impulse voltage, though there
are concomitant increased complexities.Interleaved windings require more skill and
labour than plain continuous disc windings. Sometimes a part of the winding is
interleaved while the remaining part is plai disc, so as to combine the advantages of
better impulse withstand at the high voltage end of the winding and reasonable
labour cost for the winding as a whole. These are known as partially interleaved
windings.

Voltage Regulation and Tapchanger

Voltage variation in electrical systems is a normal phenomenon, because
of rapid growth of industries and distribution network. It is very essential to maintain
the system voltage within prescribed limits for the better health of electrical
equipments. Voltage of the system can be varied by changing the turn ratio of
transformer. The device tapchanger is used for adding or cutting out turns of primary
or secondary winding of the transformer. Basically tapchanging equipment can be
divided in two categories.

1. OFF-CIRCUIT TAPCHANGER
The cheapest method of changing the turn ratio of a transformer is the use of off-
circuit tapchanger. As the name implies, it is essential to de-energize the transformer
before changing the tap.Off load tap changers are used in generating station.
An off-circuit tapchanger, consists of principally the following
three parts:

(a).Operating handle projecting outside the transformer

(b).Fixed contact with connecting terminal
(c).Insulating shaft with moving contact system.
 Off-circuit tapchanger. On load Tap Changer

2.On-load Tapchanger(OLTC)
On-load tap changers are employed to change turn ratio of transformer to
regulate system voltage while the transformer is delivering normal load.

MAIN COMNPONENTS OF OLTC

1.Tap selector
2.Oil compartment
3.Motor Drive Unit (Squirrel Cage Induction Motor)
4.Protective Relay
5.Diverter
6.Cotrol Gear

OLTC is used in furnace when we have to regulate temperature during working.

SELECTION OF TAPCHANGER
To cater for the voltage regulation in the transformer and system voltage
variation, off-circuit/on-load tapchanger is provided. Off-circuit tap switch is provided
when tapchanging is required only occasionally. Generally generator transformers
are provided with off-circuit tap switch. When tapchanging is required under loaded
conditions, on-load tapchangers are provided. Generally, unit auxiliary transformers,
station transformers, and system transformers are provided with on-load
tapchangers. The choice of tapchangers is governed by the following factors
(a).Tapping range
(b).number of steps
(c).Step voltage

(d).Current rating
(e).Location of tapping

Manufacturing and Assembly

Manufacturing and assembly of the transformer involves the following main
stages and the manufacturing techniques basically depend on the design philoso-
phy.

(a).Core building
(b).Preparation of windings
(c).Core and winding assembly

(d).Terminal gear assembly

(e).Placement of core and winding assembly in tanks.
(f).Processing

(g).Servicing and tanking

PREPARATION OF WINDINGS
The windings form the electrical circuit of a transformer. Various types of
windings, i.e. spiral, helical, disc, layer, etc. are used, depending upon the rating
of the transformer and the design considerations. Generally, low voltage windings
are either spiral or helical and high voltage windings are either layer or disc type.

The sequence of manufacture of windings is given below:

(a).Loading of moulds (formers) on the windings machines.

(b).Loading of the conductor reels on stands.
(c).Dressing of the mould, i.e. assembly of insulation spacers and blocks on
the mould.
(d).Manufacture of the winding on horizontal/vertical winding machines depend-
ing on design, type of winding, number of conductors, to be handled at a
time and the type of conductor.
 CORE AND WINDING ASSEMBLY
Core is placed on suitable levelled platform. Top-end frame and yoke lami-
nations are removed. Bottom insulation items are placed on bottom yoke/end
frame on each core leg. Various windings are either lowered one by one or com-
posite winding assembly is lowered on each core leg. After lowering of the wind-
ings, top insulation arrangement is completed. Top-end frame and yoke lamina-
tions are placed back in position. Coils are kept under pressure by either coil
clamping bolts or spring loaded hydraulic devices provided on the top-end frame.

TERMINAL GEAR ASSEMBLY

After replacing of the top yoke, the preparation of the Terminal Gear Assem-
bly done as described below:
(a).Cutting of the leads as required.
(b).Crimping/brazing of the leads with cables.
(c).Brazing of bus bars.
(d).Fixing of different cleats.

(e).Crimping/brazing of cables with terminal lugs.

PLACEMENT OF CORE AND WINDING ASSEMBLY IN TANK

After completion of terminal gear assembly, the core and winding assem-
bly is placed in the tank.Preparations include mounting of shunts, barriers, etc., on
tank walls as required and also laying of gaskets on the flange joints. In conventional
tank, the core and wnding assembly is lowered on the core and winding assembly.
In bell-shaped tank construction, top tank is lowered on the core and wind-
ing assembly.
After placement of core and winding assembly in tank, various electrical
and mechanical clearances, viz. coils to tank, line, neutral and tapping leads to
tank, etc., are checked. After the above checks are over, all the openings in tank
and cover are blanked by blanking plates and gaskets. The transformer is then
sent for drying and impregnation.

PROCESSING
The quality of a transformer and, consequently its performance and life
depends essentially on the factory processing. The assembled active part of the
transformer after tanking or before tanking as the case may be, is heated in an
oven for extraction of moisture under vacuum. Sometimes, vacuum drying is done
by drawing vacuum in its own tank and keeping the whole transformer in an oven.
Besides the conventional method of drying, the most modern vapour phoper
dry out, as otherwise windings would become loose in service, and may get dis-
torted under short circuit conditions.
Once the moisture is extracted to the desired level, oil is filled under vacuum
and the transformer is soaked in oil.

SERVICING OF TRANSFORMER
The transformer active part is then taken out and all the terminal gear cleating
of the leads are retightened and the coils are clamped and secured in position.
The transformer tank cover is then placed in its postion and the transformer is
now ready for further assembly of bushings etc.

TANKING
After servicing the transformer is assembled with all the necessary fittings.
The oil is filled under vacuum and it is circulated in order to get the desired ppm
and BDV levels before being offered for final testing and subjected to high voltage
testing.
 Testing Of Transformer
Tests of transformers are mainly classified as type tests,routine tests and special
tests.There sub-divisions are

1.Magnetising current

2.Magnetic balance

3.Isolation test

4.Ratio test

5.Winding resistance

6.Vector group relation

7.Insulation resistance

8.Capacitance tan delta

9.Separate source test

10.No load loss

11.Load loss

12.Impulse test

13.Impedance test

14.Harmonics test

15.Noise level

16.Stress

17.Vibration

18.RIV

19.RSO

20.Heat run test

21.Pollution test

22.FRL
Inside UHV test lab 160MVA 66/650 KV 3 phase testing transformer

Major equipments used in testing of transformer:-

1.Impulse generator
2.Impulse voltage divider
3.Multiple Chopping Gap
4.Cascade connected testing transformer
5.3 phase testing transformer
5.3 phase capacitor bank
6.DC voltage generator
 COOLING SYSTEM
1.NATURAL AND AIR BLAST COOLING
Detachable radiators are used to provide adequate cooling surface mounted directly
on the tank side or build up in one or two banks placed adjacent to the transformer
and connected to it by pipe work.The radiator element is made from specialy treated
sheet steel plates.Two rolled and pressed plates are welded together along the outer
edges and along the troughs between flutes.A number of such elements are welded
into a mild steel header.For increased cooling fans are provided beneath the
radiator.
2.WATER COOLING
Water cooler is usually of condenser type.Top oil is pumped around a set of tubes
through which cooling water circulates.This type of cooling reduces the space
requirement considerably and is recommended specialy for generator transformers
where plenty of cooling water is available. To prevent any possible leakage of water
into the transformer oil,oil pressure is always maintained higher than the circulating
water pressure.

3.FORCED OIL COOLING

Hot oil from top of the tank is pumped into a compact cooler with built in fans and
returned to the tank at the bottom.Alternatively a pump can be introduced to force
the oils circulation between the top and the bottom main radiator headers (where
radiators are mounted in a separate bank)

Direction of of oil flow

ACCESSORIES
OIL CONSERVATOR-
All power transformers are invariably provided with an expansion vessel called
conservator.This is to take care of the changes in oil volume due to change in
ambient temperature or as a consequence of changes in load on the
transformer.The oil level in conservator thus rises or falls, resulting in a phenomenon
called breathing.
The conservator is fitted with an oil preservation system called aircell, which is a bag
made of nitrile rubber and it floats on the oil surface inside the conservator. The
aircel inflates or deflates as the oil level in the conservator falls or rises.

BREATHER-
A breather is connected to aircell and is used to dry the air that enters in the aircell
when the transformer breathes. Tahe breather contains an absorbent material like
silica gel for absorbing the moisture present in the atmospheric air.Ai entering the
breather is first drawn through an oil seal at the bottom, and passes upwards through
the silica gel crystals through the connecting pipe at the top of the aircell.

BUCHHOLZ RELAY-
The oil and gas actuated relay serves as a protection against any loss of
oil,discharge inside the tank and interturn short circuit and insulation defects
.Indications for above faults are available from this relay even when the fault current
is too small to operate the overcurrent and earth fault relays.This device is usually
mounted in the connecting pipes between the highest point in the transformer and oil
conservator.

PRESSURE RELIEF VALVE-

This is a spring loaded safety valve mounted on the tank cover for protection of
transformer in case of sudden over pressure.
 Capacitor
Capacitor is an important element of power system. It is used in power network to
improve the quality of power supply by improving the power factor/ voltage.

There are many advantages of installing capacitor. Some of these are:

(a).It is 50 times cheaper than generation of equal power.
(b).Improvement in power factor and reduction in penalty due to lagging power
(c).Saving of power

Classification Of Capacitors.
(a). Based On Application:-
Shunt Capacitors For Power Factor Improvement
Series Capacitors For Reactive Compensation and Voltage Regulation

Filter Capacitors For Harmonic Filtering

Capacitor Voltage For PLCC, Metering & Protection

Transformer

Surge capacitors For Protection Of Generator and Transformer Winding

SHUNT CAPACITORS
Inductive loads having magnetic fields for their functioning require lagging
magnetizing kVAr. The current drawn by the inductive load will lag the ap-
plied voltage by an angle called the power factor angle. If the power factor
is low, the demand for reactive kVAr will be more Active Power will be sup-
plied by Generators and Reactive Power by proper control of excitation of
synchronous generators, transmission lines due to its capacitance effect
and by local injection with capacitors. For improving the power factor, kVAr
can be supplied either by synchronous condenser, being over excited syn-
chronous motor or by static capacitor. Synchronous Generators, when un-
der excited will absorb kVAr and work as a reactor.

Advantages of Providing Capacitors in Shunt with Load

1)Reduces lagging component of circuit current.
2)Increases voltage level at load and improves voltage regulation.
3)Reduces I R and I X power losses because of reduction in current.
4)Increases power factor of source generators.
5)Decreases loading on source generators and circuits to relieve and over-
loaded condition or release capacity for additional load growth.

SERIES CAPACITOR
When the capacitors are connected in series with the system.
ADVANTAGES:-
1).It offers the most economical solution with respect to both the steady state
and the transient stability.
2).Better reactive power balance.
3).It is effective with added voltage regulationwhen the pf is low.
4).It reduces the voltage drop by compensating line reactance and reduces
sending end kVAr demand by compensating I2 XL component of the line.

FILTER CAPACITOR
The capacitors are connected in combination of reactors and resistors to
form filter capacitor. It is used for filtering harmonics present in the system.
It is generally used in HVDC application where large amount of harmonics
are generated by Thyristor.

CAPACITOR VOLTAGE TRANSFORMER

Capacitor voltage transformer is used for PLCC and metering and protec-
tion of the line. Capacitor divider is a part of CVT. Coupling capacitor is
used only for PLCC application

SURGE CAPACITOR
Surge capacitor is used for protection of winding of generators and trans-
formers by reducing rate of rise of surges.

List of Major materials for manufacturing of Capacitor

1).Dielectric Material:
Polypropylene Film of 9 µM to 15 µM thickness.
Tissue paper of 12 µM thickness for CVT application.
2).Electrode:
High purity Aluminium Foil of 5 µM thickness
3).Dielectric Fluid:
Phenyl Xylyl Ethane (PXE) inside the box.
4).Discharge Resistors :
Discharge Resistors are used to discharge the capacitor unit to
50 volts within 10 min for the safety of the personnel as well as for
the protection of Capacitors.
5).Capacitor Box :
Cold Rolled / Stainless Steel having thickness of 1.6 mm / 1.5 mm re-
spectively
6).Bushings :
The Capacitor terminations are taken out by weldable Capacitor bushings
having voltage rating in accordance with the unit rating.
7).Capacitor Mounting Arrangement:
Capacitor units are mounted on the Galvanised or painted racks. The
Galvanising and painting thickness is more than 85 microns.
 High Voltage Condenser Bushings

Introduction
Bushing is one of the most important components that are fitted to the
electrical equipments like the transformer, the switchgear etc. It is an insulating
structure for carrying the HV conductor through an earthed barrier.
The 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

Classification of Bushings
Bushings are classified according to the following factors:

Application or Utility
a) 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 A are required.

b) Bushings for Switchgear

In the switchgear, bushings are to carry the conductors through the tank
wall, and support the switch contacts.

c) 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.

d) Wall or Roof Bushing

In recent years, many sub-stations for 132 kV and above, in unfavorable

situations have been put inside a building.
 e) Loco Bushings
These bushings are used in freight loco and AC EMU transformers for the
traction application.

f) Non Condenser and Condenser Bushing

Non Condenser Bushing

In its simplest form, a bushing would be a cylinder of insulating material,
porcelain,glass resin, etc. with the 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

In this type, the conducting cylinders are inserted in the insulation to divide the wall

thickness into a number of capacitors. In this way, the voltage distribution in the

material and along its surface can be controlled.

Insulating Material
The insulating material of bushings is usually paper-based with the following most
common types:

• Synthetic Resin Bonded Paper (SRBP)

• Oil Impregnated Paper (OIP)

• Resin Impregnated Paper (RIP)

 Design of Bushing
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
voltage. The design of a bushing depends on the various voltages and over-voltages
that it has to come across during service. In order to study the factors which
influence the design of a bushing, it is convenient to consider a transformer bushing
with one end in the air, and the other in oil. The important factors which effect the
design are:

Air-end Clearance
The air-end clearance has to be sufficient to meet the specified over-voltage
tests. It is also determined by the creepage 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 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 to 4. This ratio is denoted by  
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
Bushing 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.

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:

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.
Figure 1 Shapes of porcelain sheds Figure 2 Main parts of bushing