INDUSTRIAL TRAINING REPORT

PRESENTATION

On
Transformer Manufacturing Operation
at
Bharat Heavy Electricals Limited, Bhopal

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

MANIPAL INSTITUTE OF TECHNOLOGY

(A Constituent College of Manipal University)
MANIPAL – 576104, KARNATAKA, INDIA
 Contents
• About BHEL
• Transformer Manufacturing Process
• Major Products of BHEL Bhopal
 About BHEL
 Bharat Heavy Electricals Limited (BHEL) is an Indian state-owned integrated power plant
equipment manufacturer and operates as engineering and manufacturing company based in
New Delhi, India.
 BHEL was established in 1964, ushering in the indigenous Heavy Electrical Equipment
industry in India.
 It is one of the only 7 mega Public Sector Undertakings (PSUs) of India clubbed under the
esteemed 'Maharatna' status. On 1 February 2013, the Government of India granted
Maharatna status to Bharat Heavy Electricals Limited.
 It 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, Renewable Energy, Oil & Gas and Defence.
 It is the 7th largest power equipment manufacturer in the world. In the year 2011, it was
ranked ninth most innovative company in the world by US business magazine Forbes.
 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, UAE, Bhutan, Egypt and New Zealand.
 TRANSFORMER
DEFINITION: -
• A transformer is a static piece of apparatus used for the transferring power from one
circuit to the other without change in frequency. It can raise or lower the voltage with a
corresponding decrease or increase in current.

•A simplest of Transformer consists of the following :

1.Primary winding
2.Secondary winding
3.Linkage of the two by Mutual Inductance
4.And a laminated core

Voltage transformation ratio

• E1 = 4.44* f *N1* Øm
E2= 4.44* f *N2* Øm

E2 / E 1 = N2/N1=I1/I2
 TRANSFORMER WINDING
Types of Winding:
•Disc
•Helical, Spiral
•Interleaved

HELICAL WINDING
•To carry high current the area of cross section of the conductors should be
high. This is accomplished by adopting more no. of conductors per turn.
•Helical winding which is spring like, suits most for the LV windings.

DISC WINDING
•Large no. of turns
•Less current.
•Disc coils are the best choice for the HV windings where a single disc
can have turns as high as 25 nos.

General Winding Arrangement:

• TAP LV HV
• LV TAP HV
 INSULATION BETWEEN TRANSFORMER WINDING

•Transformer windings have insulation within the winding, between windings and windings
to earth.
•Insulation within the windings is generally paper insulations however helical and disc type
of winding has DUCTS between turns or discs.
•Paper thickness of conductor should be such that it should be able to withstand various
voltage stresses appearing during normal and transient conditions.
CORE BUILDING
•Magnetic circuit is formed by ‘CORE’ through which magnetic flux flows.
•CORE is a three or five legged construction providing the mechanical support.
•Coils which are of cylindrical shape are assembled over the legs.

MATERIAL USED IN CORE

•The material used for core making is low reluctance magnetic steel containing silicon. This is
called “CRGO” i.e. cold rolled grain oriented steel.
•The grain orientation is technology which ensures that the flux flow through the laminations
with minimum resistance, resulting in low core loss.

CRGO Imported from:

1)Nippon Steel Corporation, Yawata Works (Japan)

2)VIZ-Stal Ltd., Etakerinburg (Russia)
3)POSCO
 TRANSFORMER TANK
•Transformer tank is an enclosure which contains inside it the live parts such as core and
winding assembly, electrical connections and insulating oil.

MOST BASIC CLASSIFICATION:-

A.CONVENTIONAL
B.BELL TYPE

CONVENTIONAL TANK:

A tank in which the cover is flat and tank to cover junction is at the top of the tank.

BELL TYPE TANK:

•A tank in which the cover is not flat in shape and the tank and cover junction is near the
bottom of the tank.
•Thus tank has got two parts – ‘TOP TANK’ AND ‘BOTTOM TANK’.
 TRANSFORMER COOLING
•When the transformer is in service the windings get heated up. In oil filled power transformers
oil is the cooling medium for windings. Oil is in turn cooled by means of radiators /integral
coolers with water/air as cooling medium.

TYPE OF COOLING
(1)ONAN COOLING
•oil flow is through natural convection
•air flow is also natural(not forced)
•cooling equipment used:
-radiators
(2)ONAF COOLING
•oil flow is through natural convection
•air flow is not natural but forced
•cooling equipment used:
-radiators and fans
-ONAF coolers
(3)OFAF COOLING
•Oil flow is forced by means of inline oil pumps.
•air flow is forced by means of fans /blowers
•cooling equipment’s used:
- Radiators, fans and pumps.
or integral OFAF coolers
 INSTRUMENT TRANSFORMER

 These are used for measurement. Actual measurement is done by measuring instruments
but these transformers serve the purpose of stepping down the voltage to protect the
measuring instrument.
 They are used in AC system for measurement of current voltage and energy and can also be
used for measuring power factor, frequency and for indication of synchronism. They find
application in protection of power system and for the operation of overvoltage, over
current, earth fault and various other types of relays.

They are of two types.

1. Current transformer (CT)
2. Voltage transformers (VT)

TRANSFORMER TESTING

 A. Routine tests
 B. Type tests

Routine tests are conducted on each and every transformer of the lot/order. Type tests are
conducted on one Transformer of a particular design and on successful passing of this test the
design of the transformer is said to be validated.
Routine tests:-
•Ratio Test
•Vector Group Verification
•Winding Resistance
•Core Loss
•Load Loss
•Impedance Measurement
•Separate Source Voltage Withstand Test
•Induced Over Voltage Withstand Test

Type Tests:-
•Temperature Rise Test
•Lightning Impulse Test
•Vacuum and Pressure Test

Test Requirements:-
•In order to ensure the suitability of transformer for various possible transients/over voltages of system,
various national standards like is 2026 (part-iii) & international standard like IEC 60076-3 define the test
levels & test method requirement for different tests.

• The major dielectric tests applicable for EHV class transformers are:
1.lightning impulse withstand
2.switching impulse withstand
3.induced overvoltage with or without Pd measurement
4.separate source voltage withstand test
 Major Products of BHEL Bhopal
TRANSFORMERS
•Power Transformers up to 420kV class, 50/60 Hz 930 MVA, 3-phase Bank.
•HVDC Converter Transformers and Smoothing Reactors.
•500 MVA, ± 500kVDC, 3 winding, 1- Phase. Convertor Transformer.
•254 MVAR, 360mH, 1568A, ±500 kVDC 1 –Phase Smoothing Reactor.

INSTRUMENTS TRANSFORMERS
•Current transformers up to 420 kV.
•Capacitor voltage Transformer up to 420 kV.

REACTORS
•Gapped core Shunt Reactors up to 420 kV class, 125 MVAR 3 Phase Unit.
•Series and Neutral Grounding Reactors.
•Controlled Shunt Reactor up to 420 kV class, 80 MVAR 3 Phase Unit.
 Major Consumers of BHEL
National International
NTPC TNB, Malaysia
PGCIL PPC, Greece
NJPC MEW, Oman
NHPC OCC, Oman
NLC GECOL, Libya
NPCIL Trinidad & Tobago
NEEPCO New Zealand
JPPCL Tanzania etc.
ALL State Electricity Boards