Section- 3 Design Information

Crompton
Greaves

Section -3 Design Information

3.1 PERTINENTDESIGN CONSIDERATIONS AND SYSTEM (EQUIPMENT)
PRINCIPLEAIODE OF OPERATION .. 3-2

3.2
PRINCIPLE OF OPERATION e**oe0000000 eoeeooooe0000o ****esoeoeeseeoo . 3-3
3.2.1 PREFACE :. ********o**o*e**o**s*******eeoeoo*o*e********e********e********e********e**********************************************3-3
3.2.2 TRANSFORMER CONSTRUCTION:.. *e0*******eo******ee*******e********e****************ee***************eeeo*************o**** -3J
3.2.2.1 CORE ********°**************************************°**°*********************************°************°********************* .3-3
3.2.2.2 WINDINGS .3-3
************°**°**********°**e*****e°*******************************************°*****************************°****

3.2.2.3 CoOLING:..
*°***************************** *****************°**°***°°***°°°************°°***************°************°.3-3
3.2.2.4 TANK & cOVER.. **************** *****.*********e******e*************°******************* *** J4
3-
3.2.2.5 CONSERVATOR *******°******°"*** ********** ****** **********************°°° o**a******s * .3-4
3.2.2.6 PRESSURE RELIEFDEVICE:... .3-4
3.2.2.7
GAS &OILACTUATED(BUCHHOLZ)RELAY
3.2.2.8 SILICAGEL BREATHER.
:.
. .. . **
.3-4
-5
3.2.2.9 WINDING TEMPERATURE INDICATORS.. .3-5
3.2.2.10 OIL TEMPERATURE
INDICATOR.. .3-6
3.2.2.11 BUSHINGS.. a*********. * ********* ***a**************°*******°°*°*******°***********°**°**°********** .3-6
3.2.2.12 ON LOAD TAPCHANGER.. ********************************* *******.************** **** ***********3 - 6
3.2.2.13 CONTROL &MONITORING SYSTEM:..*******a*********** ** ******a***************** ******* 3-6

3.3 INSTRUMENT LIST WITH FUNCTIONS : 7

3.4 LIST OF VALVES, POSITION &SERVICE POSITION:. *****cooses 38

3.5 LIST OF ALARM & TRIP SET POINTS..

Customer :BSSL, T9059

Page 3-1L
 Crompton
Section 3 Design Information Greaves
3.1 Pertinent Design Considerations And System (Equipnent) Principle/Mode of
Operation
SI. Equipment Design Considerations Equipment Parameters
No. Part
1) Core 1) No load loss 90 KW CRGO Grade Steel
laminations
2) Mitred joints at the corners
2) Winding 1) Load loss 250 KW Max. 1) Current density control
2) Temperature rise
-
oil 35°C 2) Electrolytic copper
3) ONAN/ONAF/OFAF Radial and axial oil ducts
in windings for cooling
winding 45°C 4) Radial and axial supports
4) Short Circuit forces
in windings for countering
shortcircuit forces
3) Insulation HV BIL 1050 kVp 1) Insulation system with
HVN BIL 95 kVP Class-A
Paper/Pressboard and oil
LV1 BIL 170 kVp
LV2 BIL 170 kVp 2) Pressboard/oil barrier
system for core-winding
& winding-winding
Adequate oil clearances
to tank and other metal

parts
4) Cooling Temperature rise oil 35°C ONAN/ONAF/OFAF
ONAN/ONAF/OFAF cooling system with
winding- 45°C adequate number of finned
radiators, Fans, Pumps
5) Voltage Voltage variation of HV from OLTC mounted inside tank
control
+10% to-10% of HV
6) Controls Cooler controls Refer control drawings
OLTC controls
) Protection Alarm & trip contacts for adequate Refer drawing No.
devices protection of the equipment with T30B1 9059E
Protective Relays in Tr.relay panel
8) Terminations Bare Terminal for HV, LV1, LV2 & OIP Bushings for HV
Neutral
Porcelain bushings for LV1,
Lv2& HV Neutral

9 Tank Vacuum withstandability 1) Tank construction with

Oil Pressure withstandability adequate stiffeners
2) Bell tank bolted to bottom
tank.
4) SRBC/Nitrile gaskets
used for oil openings

10) Anchoring To anchor the

parts during Transport
supports
1) Location of Assembly on
Tank

Customer BSSL, T9059

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Section 3 Design Information Greaves

3.2 Princlple of Operation:

3.2.1 Preface

Transformer is a static piece of apparatus which converts electrical energy from one
voltage to another. As the system voltage goes up, the techniques to be used for the
design, construction, operation and maintenance also becomes more and more
critical.

If proper care is exercised in the installation, operation, maintenance and condition

monitoring of the transformer, it can give the user trouble free service throughout the
expected life of equipment which is of the order of 30-40 years. Hence, it is very
persons of
essential that the associated with the installation, operation maintenance
or
the transformer are thorough with the instructions provided by the manufacturer

3.2.2 Transformer Construction

The techniques used in the design and construction of high voltage transformers vary
from manufacturer to manufacturer. Our transformers are of core type construction
with the windings placed concentric to the core.

The active parts of the transformers consist of core and windings.

3.2.2.1 Core:

Core is manufactured from lamination of Cold Rolled Grain Oriented Silicon Steel
which gives very low specific loss at operating flux densities. Joints of the
laminations
are designed such that the
electromagnetic flux is always in the direction of grain
orientation. The core clamping structure is
designed such that it takes care of all the
force produced in the windings in the event of
any short circuit. The core is of 3
Phase, 3.limb design.
3.2.2.2 Windings:

Windings made from paper insulated

are
copper conductors. Parallel
transposed regular intervals throughout the winding for ensuring conductors
at are
and current distribution between strands.
Disc construction is
equal flux linkage
voltage windings to ensure uniform distribution of adopted for the high
in the windings are impulse voltages. Insulation spacers
arranged such that oil is directed through the entire
ensuring proper cooling. The disposition of windings from windings for
core are

Core-Lv2- LV1 -

HV -Tap
3.2.2.3 Cooling:

For ONAN cooling oil flows

to the tank through the
winding and external radiators units attached
by thermo syphonic effect. Radiator
sheet radiators mounted cooler units consists of
directly on the tank. ONAF pressed steel
adequate number of Fans. OFAF cooling is achieved by providing
cooling is achieved by providing by fans and pumps.
Customer BSSL, T9059
Page 3-3
 CGCrompton
Section 3 Design Information Greaves
3.2.2.4 Tank &cover
Tank and cover are manufactured by welding stoel plates and are suitatls tor
withstanding full vacuum and positive pressure of 1 atmosphere. Cover is bolted to
the tank at the curb location.

Construction of the tank and cover are such that these can be transported by
road/waterways as per customer specification.

3.2.2.5 Conservator

Conservator is provided to take care of the expanslon and contraction of transformer

oil which takes place during normal operation of the transformer.

Flexible separator oraircelis provided in the conservator to prevent direct contact of

air with the transformer oil.

A separate compartment in the main conservator is provided for the On Load

Tapchanger oil

Magnetic oil level gauge is fitted on the main conservator which can give alarm in the
faling below the pre-set levels due to any
event of the oil level reason
3.2.2.6 Pressure Relief Device :

A device for oil pressure relief for the transformer tank and cooling system is fitted with
a trip relay. The pressure relief device alows for the rapid release of excessive
pressure that may be generated in the event of a serious fault.

A pressure relief device is a spring loaded device which provides rapid amplification of
its actuating force.

A bright colour coded mechanical indicator pin in the cover moves with the valve disc
during the operation of the pressure relief device and is held in position by an 'O' ring
in the pin bushing. This pin is clearly visible from ground level indicating that the
device has operated.

The indicator pin may be reset manually by pushingit downward until it is reset on the
valve disc. The relief device is provided with a shielded weatherproof trip contact and
is operated by the movement of valve disc.

3.2.2.7 Gas & Oil Actuated (Buchholz) Relay :

Gas and oil actuated relay is fitted in the feed pipe from the expansion vessel to the
tank for collection of gas generated in the oil. A pre-set volume of gas collection in the
reiay, or an oil surge towards the expansion vessel will cause the alarm or trip
contacts to operate respectively.

in the event of serious oil loss from the transformer, both alarm and trip elements
operate in turn in the manner previously
described for gas collection.

Customer BSSL, T9059

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 ICrompton
Section-3 Design Information Greaves
Two brass petcocks are fitted at the top of the relay body, the outlets of which are
threaded to take a bleed pipe, if required, for collecting gas samples.

In the pipe connection between On Load Tapchanger and its oil exparnsion vessel an
oil surged relay is fitted. This relay operates on the principle of oil surge impinging on
a flap causing operation of the merury switch connected to the trip circuit. Gas
actuated alarm switch is eliminated because the gas generated during normal tap
changing operation will give unnecessary alarm.

3.2.2.8 Silicagel Breather

Expansion and contraction of oil cause breathing action. Any humidity in the air
breathed is absorbed by the silicagel dehydrating breather. An oil seal in the air intake
prevents external moisture being absorbed when no breathing occurs.

The breather container is filled with silicagel crystals. It is arranged such that the air
breathed must pass through it. The desiccant is impregnated with cobalt chloride and
when the silicagel crystals are fully active, they are of deep blue colour. If colour
changes to a whitish pink, they are then saturated with moisture and the charge
container should be replaced by a new reactivated one.

The size of the breather is chosen to operate effectively over a period of six months
approximately. The amount of silicagel required is dependent upon the quantity of oil
in the transformer, the load cycle and the atmospheric conditions on site. The last two
conditions are difficult for the transformer manufacturer to access so that a
periodic
inspection of the indicator should be made for safe operation.

3.2.2.9 Winding Temperature Indicators:

The winding temperature relay indicates the winding temperature of the transformer
and operates the alarm, trip and cooler control contacts.
Winding temperature indicator consists of a sensor bulb placed in an oil filled pocket in
the transformer tank cover. The bulb is connected
to the instrument
means of two flexible
capillary tubes. One capillary is connected to the housing by
measuring
bellow of the instrument and the other to a
compensating bellow. The measuring
system is filled with a liquid which changes its volume with rising of temperature.
Inside the instrument is fitted a heating resistance
which is
proportionate to the current flowing through the transformer winding. fed by a current

The instrument is
provided with a maximum temperature indicator. The
resistance is fed by a current transformer heating
transformer. The increase in the associated to the loaded winding of the
of the winding. The temperature of the resistance is proportionate to that
sensor bulb of the instrument is
transformer, therefore, the winding located in the hottest oil of the
temperature
plus the winding temperature rise above hot oil indicates a
temperature of hottest oil
i.e. the hotspot temperature.

Customer BSSL, T9059

Page 3-5
 Crompton
Section 3 Design Information Greaves
3.2.2.10 Oil Temperature lndicator
consist of a sensor bulb, capillary tube and a
dial
The oil temperature indicator cation of hottest oil. The sensor bulb
thermometer. The sensor bulb
is fitted at the
with an evaporating liquid. The vapour pressure varies
and capillary tube are fitted
to a bourden tube inside the dial thermometer
with temperature and is transmitted
in pressure which is proportional to the
which moves in accordance with the changes
temperature.

3.2.2.11 Bushings
the windings to terminai bushings. Terminal
The winding connection pass from
of plain porcelain and oil communicating
bushings upto 36 kV class, are normally are of oil impregnated paper condenser
type. Bushings of 52 kV class and above will not be communicating with the oil
type. The oil inside the condenser bushings
inside the transformer. Oil level gauge is provided on the expansion chambers of the
condenser bushings.

3.2.2.12 Onload tapchanger

Transformers is provided with On load tapchanger. Tapchanging can be designed for
changing the taps in following modes:

Manually from Local Motor Drive unit

a Manually from Remote
b)
The on load tapchanging will be a self contained unit housed in the main transformer
tank. This consists of diverter unit and selector unit. In selector unit, termination will
be made. Since some amount of arcing takes place during the switching operation
from one tap to other, the oil inside the diverter unit will deteriorate faster. Hence, this
oil in diverter chamber cannot be allowed to mix with the oil in the main transformer.
On load tapchanger is provided with a separate conservator and oil surge relay.

3.2.2.13 Control&Monitoring System

Local control and monitoring of the cooler, Alarm and trip circuit are provided out at
the marshalling box. Local Tapchanger control is provided at the Drive Mechanism.

Customer: BSSL, T9059

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 Crompton
Section 3 Design Information Greaves

3.3 Instrument List with Functions

SI. Item No. of Description Function Code
GA Drawing
1) 301 Buchholz Relay Provided with alarm & trip
contacts to protect e
transformer from surges and
any internal faults

2) 302 Oil Surge Relay Provided with trip contact to

transformer and tapchanger
from any abnormal surges
during tapchange
3) 306 Magnetic Oil Level Gauge To indicate oil level in
(Main Conservator) conservator and give alarm if
oil level is minimum
4) 312 Winding Temperature To indicate the winding
Indicator (WTI) temperature. Provided with
contacts to switch ON/OFF
cooling fans and also provided
with alarm & trip contacts

5) 313 Oil Temperature IndicatorTo indicate the top oil

(OTI) temperature. Provided with
alarm & trip contacts
6) 329 Pressure Relief Device To release the excessive
(PRD) pressure in case of fault
rapidly and instantaneously. It
is provided with contacts to
trip the transformer

Customer BSSL, T9059

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Section 3 Design Information Crompton
Greaves
3.4 List of Valves, Position & Service Position :
(Refer Valve Location Plate)

3.5 List of Alarm& Trip Set Polnts

Sl. Item No. of

Description Alarm Trip
GA Drawing

1) 301 Buchholz Relay Pre-set Pre-set

2) 302 Oil Surge Relay Not applicable Pre-set

3) 306 Magnetic Oil Level Gauge Pre-set Not applicable

(Main Conservator)
4) 312 Winding Temperature 100°C 110°C
Indicator (WTI)

5) 313 Oil Temperature Indicator 85°C 95°C

(OTI)
6) 329 Pressyre Relief Device (PRD) Not applicable Pre-set

| Customer BSSL, T9059

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