Areva "Manufacturing of transformer, uses & it’s accessories"
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Areva "Manufacturing of transformer, uses & it’s accessories"

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This is the presentation on how transformer are manufactured in Areva factory , it gives detailed view of tranformers and uses too.

This is the presentation on how transformer are manufactured in Areva factory , it gives detailed view of tranformers and uses too.

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    Areva "Manufacturing of transformer, uses & it’s accessories" Areva "Manufacturing of transformer, uses & it’s accessories" Presentation Transcript

    • Manufacturing Of Transformer & It’s Accessories Harshit Srivastava Department Of Electrical And Electronics Engineering Fall Semester 2010 Roll No. 0705621028 29-08-2010 1
    • INTRODUCTION This presentation is an overview of some of the ideas and techniques used by Areva T&D Ltd. In developing transformers. In Areva the transformer development department is mainly divided into 3 categories: 1. Power Transformer ( P.T) 2. Medium Power Transformer (M.P.T) 3. Distributed Transformer (D.T) 29-08-2010 2
    • Topics 1. Introduction of Areva 2. Steps for manufacturing of transformer I. Overview of steps II. Relationships between them 3. Uses of transformer 4. Accessories of Transformer 5. Steps done to solve issues in industries 29-08-2010 3
    • AREVA T&D WITHIN THE GROUP T&D: 1/3 of AREVA’s energy business 29-08-2010 Source: 2010 AREVA annual report 4
    • COMPLETE PORTFOLIO OF ELECTRICITY TRANSMISSION & DISTRIBUTION Products Power Transformers Generator Circuit Breakers Disconnectors Instrument Transformers Primary Distribution Gas-Insulated Secondary Distribution Substations Circuit Breakers Distribution Transformers Systems Substations Power Electronics Distributed Energy Power Distribution Automation Automation Products Automation Systems Automation Support Service Maintenance & Repair 29-08-2010 Erection & Commissioning Retrofit Spare Parts Total Asset Care Training & Network Consulting 5
    • PRODUCT LINE - POWER TRANSFORMER 29-08-2010 6
    • PTI - Technology Worldwide Manufacturing Facilities Stafford United-Kingdom Mönchengladbach Germany Jakarta Indonesia Le Petit-Quevilly France Saint-Ouen France Shanghai China Naini India Gebze Turkey Brisbane Australia Canoas Brazil 29-08-2010 7 Power Transformer March 2002- 7
    • Manufacturing Process Of Transformer RAW MATERIAL • Raw material basically used is CRGO(cold rolled grained oriented)silicon steel. • The purpose of using CRGO is to reduce the Hysteresis Losses. CORE CUTTING • It is in the form of thin sheets & cut to size as per design. • Generally three different shapes of core laminations are used in one assembly. COIL WINDING • Coil Winding is of two types:• R-S COIL • HELICAL COIL • SPIRAL COIL CORE FITTING ASSEMBLY 29-08-2010 • The core assembly is vertically placed with the foot plate touching the ground. the top yoke of the core is removed. The limbs of the core are tightly wrapped with cotton tape and then varnished. • The coils as specified in the design may be of following types: • L.V COIL • H.V COIL 8
    • TESTING TANKING • COIL WINDING • CONNECTION • Tanking is a procedure of embracement of complete unit (active unit) in a mild steel tank, the unit being enclosed includes (core entrapped with windings). • ROUTINE TEST • RATIO METER METHOD • DIELECTRIC TESTS TESTING AT • IMPULSE TEST LEVELS POWER LEVEL • TEMPERATURE RISE TEST DISMANTLIN G& DISPATCH 29-08-2010 • After testing is completed and before dispatch from the factory all necessary work, e.g. removal of bushings etc. shall be performed. • A shipping list is made concerning the General arrangement drawing which list out the external attachments of a power transformer to be send to customers . 9
    • RAW MATERIAL USED  MATERIAL- CRGO SILLICON STEEL  DIFFERENT GRADES OF CRGO  CTC-Continuous transposed material  TYPICAL LOSS VALUE (W/Kg) AT 50 Hz & B (Tesla) GRADE LOSS VALUE CRGO B (Telsa)  27M-4 0.83 1.22  MOH 0.72 0.99  ZH100 0.70 0.96  ZDKH90 0.60 0.83 29-08-2010 CTC (Continuous Transposed Conductors) 10
    • CORE CUTTING E shape I shape V shape 29-08-2010 11
    • COIL WINDING HELICAL WINDING 29-08-2010 CONTINUOUS DISC WINDING SPIRAL WINDING INTERLEAVED DISC WINDING 12
    • CORE FITTING  CONSTRUCTION 1.THREE LEG (NORMAL) 2.FIVE LEG (TO REDUCE HEIGHT)  CLAMPING ARRANGEMENT 1.END FRAME & INSULATION 2.CLAMPING PLATES 3.YOKE BOLTS OR YOKE STEEL BAND (NO HOLE PUNCHING REQ )  PROPER TIGHTENING TO REDUCE NOISE LEVEL 29-08-2010  VARNISH AT EXPOSED SURFACES 13
    • The steps are being continued.. 29-08-2010 14
    • ASSEMBLY(BEFORE TERMINAL GEAR STAGE)  TOP YOKE REMOVAL  LEVELING OF BOTTOM SUPPORT BLOCK  LEG PREPARATION VISUAL CHECKING OF COIL  LOWERING OF COIL IN PROPER ORIENTATION  TOP INSULATION & CLAMPING RINGS  MOUNTING OF ENDFRAMES  SHRINKAGE IN HEATER  TOP YOKE FITTING  BTG TEST FOR CHECKING CORRECTNESS 29-08-2010 15
    • TESTING CORE ASSEMBLY COIL MANUFACTURING TYPES OF TESTS  STAGE TESTING ( DURING MANUFACTURING STAGE)  ROUTINE TEST AFTER TG STAGE DRYING & PROCESSING  TYPE TEST FINAL SERVICING  SPECIAL TEST 29-08-2010 FINAL TANKING,OIL FILLING 16
    • TANKING Oil filling station where tanking is done 29-08-2010 17
    • DISMANTLING & DISPATCH Shipping list Commissioning Physical inspection of tank before placing it Onto trailor Final inspection for traveling point of view 29-08-2010 18
    • PRECAUTION & GENERAL PRACTICES IN COIL ADOPTED • PRECAUTION Conductors with rounded of edge Strip & spacers shouldn't have sharp edges Clean winding & insulation shop • STABILISATION OF WINDINGS Alignment 2 to 3 heating cycle & pressing under hydraulic press HYDRAULIC PRESS FOR COIL 29-08-2010 19
    • POWER MARKET Estimated capacity shortfall in GW 5-10 x Scale-up REQUIRED IN RATE OF CAPACITY ADDITION Annual Capacity Addition in GW / year Source: Powering India – Road to 2017, McKinsey 2008 29-08-2010 If business as usual continues…India is likely to face a capacity shortfall of 95140 GW by 2017 Source: Powering India – Road to 2017, McKinsey 2008 20
    • TECHNOLOGY REQUIREMENTS  ULTRA MEGA POWER PROJECTS- LARGE GENERATOR TRANSFORMER -936 MVA  POWERGRID AS MAIN NODAL AGENCY  FORMATION OF CENTERAL GRID  INTERCONNECTION OF GRIDS 29-08-2010 21
    • TECHNOLOGY CHALLENGES  765kV System & Network  800kV HVDC Transmission  1200kV Development System 29-08-2010 22
    • USES Uses Power Transformers are used for a variety of reasons, but they all have one thing in common; namely that the power being received must be tailored for the specific use. 29-08-2010 23
    • 29-08-2010 24