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Prepared by:            Jimit Dhruv         Elect.Engg,Dept.Valiya Institute Of Technology-Valiya
Introduction Core material:   Basic material are Alloy Steel having main    content Silicon & carbon   Which increases ...
 HRS:   HRS not used now a days   As it has random direction &hard to measure   Magnetic properties CRGOS:   CRGOS sh...
Core construction Due to Pulsating flux, core should be  laminated Transformer of larger size may forms in  cut “C” or c...
Transformer winding
Concentric                                       Sandwich Spiral: It is used 100  A& for low Voltage  Winding    Mechani...
InsulationsTwo main kinds of Insulations:1. Major Insulation:    Insulating cylinder between LV & core    Also between H...
Bushing Up to 66kv non-condenser bushing are used is  porcelain & oil filled Above 66kv condenser bushing are used for  ...
Tapping Main two location:  1. Inside Tank  2. Outside Tank Considered as integral part of transformerTapping operation ...
Transformer Tank Plain sheet steel  Tank Tube Tank Corrugated Tank Radiator Tank Tank with separate   coolers
Conservator What is Conservator ? The expansion of oil from Transformer  tank takes up in Conservator When oil contract...
Buchholz Relay Operation: Gas operated relay AT the time of fault to maintain the continuity  of the supply Fault dete...
Transformer oil Double purpose :   ie cooling & Insulating Permittivity is 2.5 As per I.A.S breakdown strength of oil ...
WORKSHOP(TPT DEPT.)WINDING SHOP  CORE & ACTIVE PART      FINAL ASSEMBLY          QUALITY TEST             FINAL TESTING
WINDING SHOP TYPES OF WINDING   i.   NORMAL WINDING   ii. INTERLEAVE WINDING   iii. TERITARY WINDING                     ...
 Conductor Insulation:    1. Precompressed press board insulation(CRIP       PAPER)    2. Craft paper    3. Also spacers ...
 PROCEDURE:
CORE & ACTIVE PART ACTIVE PART C.R.G.O. STRIPS 1-STRIP HAS WIDTH OF 0.27 mm COIL OR WINDING ASSEMBLY PROCEDURE: Manu...
FINAL ASSEMBLY Installation of active part and assembly of  accessories TRANSFORMER TANK                      • JOINED A...
 ACCESSORIES:  Blanker : Leakage of oil & Radiators  adjointment  Buchholz Relay: To trip the transformer  OSR (oil se...
 Method of Cooling:    i.   ONAN    ii. ONAF    iii. OFAF    iv. For very high temp using HEAT         EXCHANGER CT(Curr...
 PROCEDURE  Vacuuming of Tank(up to 0.3 mbar) for about   24hrs to 36hrs  The Leak Rate Test with the use of water & ai...
QUALITY TEST ANALYSIS WITH “SIGMA CARD” Sigma card includes below required data    Design    Process Time    M/C size...
FINAL TESTING                  ROUTINE TESTS   TYPE TESTSNO LOAD TETS                                                     ...
CT (CURRENT TRANSFORMER) Generally CT is use for the below four  purposes:    Measurement of Current    Measurement of ...
 Quartz in CT Reduces the quantity of oil Provides mechanical strength for the    conductors   Improves the quality of...
Thank You
PRESENTATION ON MANUFACTURING OF TRANSFORMER By Dhruv Jimit
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PRESENTATION ON MANUFACTURING OF TRANSFORMER By Dhruv Jimit

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THIS PRESENTATION WILL GIVE A GREAT KNOWLEDGE OF MANUFACTURING OF PRACTICAL AS WELL AS THEORETICAL TRANSFORMERS.

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  • How many earthing used as per IS between Core &body
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  • Well presented. May add a reference to lightining protection
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  • hello Mr. Jimit dhruv , send me copy at vipinsingh541991@gmail.com
    thanx....
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  • thank you jimitdhruv,send me a copy and also its financial aspect ,costing and human resource and materials used and where to get them
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PRESENTATION ON MANUFACTURING OF TRANSFORMER By Dhruv Jimit

  1. 1. Prepared by: Jimit Dhruv Elect.Engg,Dept.Valiya Institute Of Technology-Valiya
  2. 2. Introduction Core material:  Basic material are Alloy Steel having main content Silicon & carbon  Which increases permeability & reduces losses
  3. 3.  HRS:  HRS not used now a days  As it has random direction &hard to measure Magnetic properties CRGOS:  CRGOS shows excellent Magnetic properties  So CRGOS is more used
  4. 4. Core construction Due to Pulsating flux, core should be laminated Transformer of larger size may forms in cut “C” or cut “E” type. Types of Interleaving: I. Simple Interleaving II. Meter core Interleaving: 1)45 ˙ 2) 33 ˙ /55 ˙ overlapping  In 3-Ø Shell type transformer middle winding is reversed  If not then 73% more core is used which leads in increase in over all cost
  5. 5. Transformer winding
  6. 6. Concentric Sandwich Spiral: It is used 100 A& for low Voltage Winding  Mechanically very strong  Sandwich: mostly used Helical :Intermediate for shell type transformer range of current  Control leakage  Suitable for LV winding reactance of large transformer  HV & LV are near so leakage flux is reduced Cross-over: suitable of  mmf of each section is current not exceeding 20 same. A  Use for HV winding of small transformer Continuous disc: no of turns wound radially over one another  separated by spacers  HV winding  Mechanically strong
  7. 7. InsulationsTwo main kinds of Insulations:1. Major Insulation:  Insulating cylinder between LV & core  Also between HV & LV  Insulating barriers between limbs, coils & core yoke  Oil impregnated paper used as it has high dielectric strength2. Minor Insulation:  Insulation between individual turns & between layers  Conductor Insulation: paper&cotton  Air insulated Transformer insulation used is glass tap
  8. 8. Bushing Up to 66kv non-condenser bushing are used is porcelain & oil filled Above 66kv condenser bushing are used for economic reasons. Condenser type bushing: It is formed by inserting Aluminum foiled layers into a paper winding at predetermined radius. “Partial capacitance” In outdoor substation the bushing are covered by a porcelain rain shade
  9. 9. Tapping Main two location: 1. Inside Tank 2. Outside Tank Considered as integral part of transformerTapping operation (1)On load (2)Off loadtap changer tap changer Tapping is terminated just bellow oil level External handle Taping is done on HV winding Provided in middle (axial & radial force)
  10. 10. Transformer Tank Plain sheet steel Tank Tube Tank Corrugated Tank Radiator Tank Tank with separate coolers
  11. 11. Conservator What is Conservator ? The expansion of oil from Transformer tank takes up in Conservator When oil contracts, air from atmosphere enters in Conservator . Risk of contamination of oil in transformer Breather valve is mounted to avoide moisture Breather contain silica in it
  12. 12. Buchholz Relay Operation: Gas operated relay AT the time of fault to maintain the continuity of the supply Fault detected particularly in incipient stage , major fault can be avoided Which is placed between conservator and transformer tank
  13. 13. Transformer oil Double purpose :  ie cooling & Insulating Permittivity is 2.5 As per I.A.S breakdown strength of oil used must be 50kv RMS Major disadvantage is sluging To overcome this, synthetic oil is prefered One of the e.g is Chlorinated dephenyl is a synthetic oil its permittivity is 4.5
  14. 14. WORKSHOP(TPT DEPT.)WINDING SHOP CORE & ACTIVE PART FINAL ASSEMBLY QUALITY TEST FINAL TESTING
  15. 15. WINDING SHOP TYPES OF WINDING i. NORMAL WINDING ii. INTERLEAVE WINDING iii. TERITARY WINDING ROTARY HORIZONTAL HELICAL K- MACHINES TRANSPOSITION TYPE CONTINUOUS VERTICAL DISC• End Rings & shielding for prevention purpose
  16. 16.  Conductor Insulation: 1. Precompressed press board insulation(CRIP PAPER) 2. Craft paper 3. Also spacers as insulation Moisture Control  Winding Auto Clave: Uses temp. of 110º C to 130º C and Vacuum of about 0.4 to 0.5 mbar.  Insulating Oven : Uses Heating Only Pressure Machine Brazing Machine with use of SILPHOS ALLOY Post Insulation
  17. 17.  PROCEDURE:
  18. 18. CORE & ACTIVE PART ACTIVE PART C.R.G.O. STRIPS 1-STRIP HAS WIDTH OF 0.27 mm COIL OR WINDING ASSEMBLY PROCEDURE: Manufacturing of LIMB Core Insulation Removal of TOP FRAM for Coil assembly Winding insulation detail TOP YOKE FILLING VAPOUR PHASE OVEN HV & LV leads from top & bottom to the bushings REGULATING COILS to the tap changer
  19. 19. FINAL ASSEMBLY Installation of active part and assembly of accessories TRANSFORMER TANK • JOINED AT BELL TYPE BOTTOM SIDE • JOINED AT CONVECTIONAL TYPE UPPER SIDE
  20. 20.  ACCESSORIES:  Blanker : Leakage of oil & Radiators adjointment  Buchholz Relay: To trip the transformer  OSR (oil serge relay): To indicate the level and quality of oil  MOLG(magnate oil gage): It indicates the level of oil in the conservator  Breather Valve: Provide dry air using silica gel and have air seal of neoprene  Cooling Equipment: Generally for cooling of oil in a tank 1. Radiators 2. Thermosyphan
  21. 21.  Method of Cooling: i. ONAN ii. ONAF iii. OFAF iv. For very high temp using HEAT EXCHANGER CT(Current Transformer):Two purposes; 1. Winding temp indicator (WTI) 2. Oil temp indicator (OTI) BUSHINGS: The leads from top and bottom of the winding are brought out to a length of few cm only and the outdoor terminal of the transformer are provided by bushings
  22. 22.  PROCEDURE  Vacuuming of Tank(up to 0.3 mbar) for about 24hrs to 36hrs  The Leak Rate Test with the use of water & air  Oil Test which includes BDV & PPM  Oil Filling  After the IMPREGNATION TIME the whole accessories are to be attached.
  23. 23. QUALITY TEST ANALYSIS WITH “SIGMA CARD” Sigma card includes below required data  Design  Process Time  M/C size specification  Process of manufacturing  Dimension specification  Testing specification  Information about control points
  24. 24. FINAL TESTING ROUTINE TESTS TYPE TESTSNO LOAD TETS TEMPRETURE TEST LOAD LOSSINSULATION IMPULSE TEST TESTCAPACITANCE & ZERO SEQUENCE TAN δ IMPEDANCE TEST SEPARATE SOURCE HARMONIC AND NOISE LEVEL TEST INDUCED OVER VOLTAGEWINDING TEST VOLTAGE RATIO
  25. 25. CT (CURRENT TRANSFORMER) Generally CT is use for the below four purposes:  Measurement of Current  Measurement of Power  Isolation between High voltage and Low Voltage  Inputs to Relays & Protection Systems PROCEDURE OF CURRENT TRANSFORMER: CO NDUCTORS USES :ALUMINIUM OR COPPER(HIGH CURRENT RATING) In the manufacturing of the primary winding or protection core there will be the creation of the capacitance as below.  GRADING & SUB GRADING.  MAIN GRADING HAS WRAPPED ALUMINIUM FOIL & CRIP PAPER  AT 300MM DISTANCE PERFORATED ALU. FOIL (400MM) AND CRIP PAPER.  SIMULTANEOUSLY INSULATION MAKE CAPACITANCE
  26. 26.  Quartz in CT Reduces the quantity of oil Provides mechanical strength for the conductors Improves the quality of oil by absorbing moisture Being a bad conductor of heat, it allows slow heating /cooling of the CT. Finally expansion tank is attached and after that evacuation of oil and gas filling will be there . There is also one imp term is D3 point which is also called the earth point.
  27. 27. Thank You

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