Power Transformer Training Presentation at B.K. Birla Group

PRESENTATION
TRAINING ON
POWER TRANSFORMER
AT
03/12/16

B.K BIRLA
GROUP,SONIPAT,INDIA
TRANFORMER DIVISION
03/12/16

We would like to thank Mr. Ramachandran (Vice
President of ECE Industries,transformer division)
and Mr. Mukul Sharma (HR of ECE
Industries,transformer divison) for allowing us to be
a part of their rich and learning enviroment.
Not to forget the role of Mr. Harish Tomar
(personnel officer) and Mr. Prashant Yadav who
guided us through all the departments and ensured
our convenient stay right through all these months.
03/12/16
03/12/16

WHY POWER
TRANSFORMER??
SINCE OUR INTEREST WAS IN
TRANSFORMER AND KEEPING IN
RESPECT THE GROWING
DEMAND OF ELECTRICITY, WE
OPTED FOR THE PREMIER
MAKERS OF POWER
TRANSFORMER IN NORTH03/12/16

•
ECE legend began as early as 1945 in
Calcutta during World War days and
steadily emerged as a growing industrial
enterprise in the Indian Electrical Industry.
Over the years, ECE has built up a
commendable infrastructure and
investment in technical know-how,
research & development.
03/12/16

• ECE is a regular and approved supplier
of power transformer upto 220 kv class to
various state government utilities and
industrial sector.
• More than 84,000 11kv distribution
transformer are working made by ECE all
over the country.
03/12/16

TRANSFORMER??
It a device that transfers electrical energy from one
circuit to another through inductively coupled conductors
—the transformer's coils. A varying current in the first or
primary winding creates a varying magnetic flux in the
transformer's core, and thus a varying magnetic field
through the secondary winding. This varying magnetic field
induces a varying electromotive force (EMF) or "voltage"
in the secondary winding. This effect is called mutual
induction.
03/12/16

Whenever there is change in flux ,
induce emf is produced in it.
03/12/16

WORK
INSTRUCTION
FOR ORDER
DESIGN
03/12/16

Receipt for work order from
marketing with customer
specification statutory &
regulatory requirement
Entry in wok order register
Design inputs are documented &
checked for adequacy
03/12/16

Adequacy check
ok
Marketing
department to get
clarification from
customer and give
it to design
department
Preparation of
design &
development plan
NO
YES
03/12/16

Preparation of work order
electrical design & electrical
stage design output
(BOM,wdg data, and testing
detail)
Design review (after electrical
design)
Any change in design due to
recommendation in design
review
Take into
consideratio
n the
recommenda
tions
received
design
YES
NO
03/12/16

Verification electrical
design,
Release of electrical design
stage design output
planning
Prepare customer
drawing
Verification of customer
drawing, customer
specification/03/12/16

Release of customer
drawing to marketing
for approval
Any change in
drawing due to
customer comment
Resubmit
customer
drawing after
incorporating
comments
(if required)
Prepare manufacturing
drawing
Design review (after
mechanical design)
YES
NO
03/12/16

Any change in
mechanical design
due to
recommendation in
design review
Take in to
consideration the
recommendation
s received design
review
Verification
mechanical design
Release of mechanical stage design
outputs to planning manufacturing
drawing
END
YES
NO
03/12/16

PROCESS OF POWER
TRANSFORMER MAKING:
1} DESIGNING
2} WINDING
3} CORE CUTTING ASSEMBLEY(CCA)
4} CONNECTIONS
5} FABRICATION
6} OIL FILLING
7}TESTING
8} TANKING
03/12/16

Types of Windings:
1. Cross-over Winding
2. Spiral winding: (i)Single layer
(ii)Double layer
(iii)Multi start
3. Helical winding: (i)Single Helical
(ii)Double Helical
(iii)Multistart Helical
4. Disc winding: (i) Continuous disc
winding
(ii) Interleaved disc
winding

2.SPIRAL WINDING
• Spiral winding is mainly used as Low
Voltage winding where current rating is
up to 3500 Amps & voltage rating is up to
6.6 KV.
• Spiral winding is also called Layer type or
cylindrical winding.
• This windings are wound in inclined angle
corresponding to height of the conductor
and insulation provided between turns.
• Rectangular or round conductors are used
for these type of winding with one or
more conductor placed radially or axially.
• These conductors are wound on flat side
with their long sides parallel to core axis.
• Sometimes they wound on rib side (edge
wise) to meet design parameters.

3.HELICAL WINDING
 The helical winding is suitable for Low
Voltage winding in medium and high
capacity transformers where number of
winding turns is small but the current is
high .
 Helix winding has three types of winding.
a) Single helical
b) Double helical
c) Multilayer helical

(a) Single Helical Winding
 The current rating of Single helical winding is
1200 amperes (maximum).
 The conductor is rectangular in cross section
and is paper covered.
• The single helical winding has its turns wound
in an axial direction with an inclination
corresponding the height of the conductor and
an oil duct provided between the turns.
• The winding consist of single section conductor
or a number of strands in parallel-radial wise.
• The parallel connected strips are placed side by
side in a radial direction so that each conductor
occupies the total radial depth of the winding
and adjacent turns separated by spacers along
the axial length.

CONTINUOUS WINDING INTERLEAVED
WINDING
It can be done if there is
single conductor or many
conductors.
It can’t be done if there is
only one conductor or odd
number of conductors.
There is no need of cutting
& brazing of conductors.
The winding is required to
be cut & brazed.
The conductor goes from
starting to end
continuously.
In interleave the last end
of one disc is cut and
joined with the starting end
of another disc.
Used for LV & HV winding. Used for HV winding only.

31
WHAT IS FORMER?
• FORMER IS A ONE CYLINDER SHAPE
WHICH IS USED FOR WOUND THE COIL.
WHY IT IS REQUIRED?
• WHEN WE WOUND THE COIL ON THE
FORMER SO COIL SHAPE MAKE
CORRECTLY ROUND BY THE CYLINDRICAL
TYPES FORMER ARRANGEMENT.

03/12/16 RAJPUT DILIP 32
GENERAL ARRANGMENT OF
M.S FORMER
shaft
stiffener
pipe
ring
flith plate

Coils are wound with Electro-lytic
grade, high conductivity, paper
covered or synthetic enamelled
copper conductor. Cooling Ducts are
provided to keep the hot spot
temperature as low as possible. Coils
are dried in electric oven. Rigid connection
support & coil clamping is provided to
ensure high short circuit strength
03/12/16

Winding is performed in the dust-proof
airconditioned and humidity-
controlled
room in order to raise the quality of product.
The transformer coils are made of
electrolytic copper strip conductors
with rectangular cross-section and rounded
corners which are wrapped with several layers
of kraft paper. Several winding
methods are employed to meet the
requirement of the customers.
03/12/16

COOLING DUCTS
• In order to prevent transformer from
heating and thus providing cooling and
insulation, cooling ducts are used.
• It is vertical in shape and allows free
moment of transformer oil within the core.
03/12/16

• Winding basically
consists of 99% pure
copper material.
• And is covered by a
paper material called
insulating material.
03/12/16

Copper is
being ordered
from Bhopal
but ECE is
planning to
open its own
copper plant
soon.
03/12/16

First when coil is completed wound then plastic
cover wound on the coil
03/12/16

Plastic cover is use for to prevent to
moisture & dust
03/12/16

When plastic cover is wound then after
tension belt is provide for coil lifting
03/12/16

When coil is lifting then after coil is
put on the roller
03/12/16

The quality silicon steel strips are cut by
modern automatic cutting machine
into sheets. These sheets are stacked
horizontally on the core raising table,
each corner being carefully miter-jointed to
make the best use of properties
of the core material. The stacked core is
clamped to the table and is gradually
raised to the upright position together with
the table to avoid undue mechanical
stress in the core, so that high quality of the
core can be assured.03/12/16

Toroidal cores and ring cores offered by us
find usage in mains transformers and are
wound from cold rolled grain oriented
(CRGO) silicon steel strips to provide
optimum performance. These toroidal cores
and ring cores are wound by automatic core
winding machine and are annealed in high
vacuum furnace under protection atmosphere
or in continuous tunnel furnace, which results
in features like compact volume, light, low
magnetic leakage and hum & high efficiency.
03/12/16

PURPOSE
• GENERALLY INSULATING MATERIAL
ARE USED FOR ELECTRICAL
ISOLATION.
• SOLID INSULATING MATERIAL ALSO
PROVIDE MECHANICAL STRENGTH TO
EQUIPMENT ASSEMBLY.
• LIQUID TYPE INSULATEING MATERIAL
LIKE TRANSFORMER OIL PROVIDE
COOLING ALSO.
03/12/16

TYPES OF INSULATING
MATERIAL
• THERE ARE THREE TYPES OF
INSULATING MATERIAL.
(1) SOLID INSULATING MATERIAL.
- KRAFT PAPER
- CREEP PAPER
- PRE COMPRESSED PRESS BOARD
- PERMALI WOOD
03/12/16

(2) LIQUID INSULATING MATERIAL.
- TRANSFORMER OIL
(3) GASIOUS INSULATING MATERIAL.
- SF6
03/12/16

CHARACTERISTICS OF
INSULATING MATERIAL
• ABLE TO MEET ALL PERFORMANCE
SPECIFICATION .
• PROVIDE ELECTRICAL, MECHANICAL
AND THERMAL REQUIREMENT.
• SHOULD BE ECONOMICAL.
• ENVIRONMENTAL IMPACT.
• RELIABLE.
03/12/16

INFLUENCE OF
INSULATING MATERIAL
• SELECTION OF INSULATING MATERIAL
CAN HAVE A SIGNIFICANT INFLUENCE
ON PERFORMANCE OF POWER
EQUIPMENT.
• PERFORMANCE IS A CAPABILITY OF
EQUIPMENT TO MEET ITS OPERATING
SPECIFICATION AND INCLUDES
ELECTRICAL, MECHANICAL AND
THERMAL PERFORMANCE.
03/12/16

• IN ORDER TO CONSIDER THE
INFLUENCE OF
• INSULATING MATERIAL CHOICE, IT IS
NECESSARY TO UNDERSTAND
PRESENT HIGH VOLTAGE DESIGN
PARAMETERS AND EVALUATE
EFFECT OF CHANGING PARAMETERS.
03/12/16

It is necessary to bring leads out from
transformer tank, to be able to make connection
with external lines. This is accomplished by
terminating these leads through
‘bushing’.
A bushing is a structure carrying a
conductor through a portion in the tank
and insulating the conductor from partition.
03/12/16

Details about bushings:-
Bushing comprises a central conductor surrounded by
graded insulation. A bushing is necessary when a conductor
is taken out through tank.
Simple porcelain insulator bushing can be used up to 20
kv class. Such a bushing consists of a single porcelain
housing through which a single conductor passes.
Oil filled bushings are used up to 33kv applications. For
making the bushing compact, synthetic resin bonded
condenser bushings (S.R.B.P. CONDENSER) is used for
33kv and 66kv applications.
For 132kv and above oil impregnated paper condenser
bushing is used. (O.I.P CONDENSER BUSHING).
03/12/16

Following are some important tests carried out
on HV bushing:-
1.Measurement of D.C. resistance between
terminals of Conductor.
2.Temp. Rise test.
3.Short circuit test for one second.
4.Dielectric tests.
5.Partial discharge test.
Routine test carried out on bushing:-
1. Measurement of insulation resistance.
2. Measurement of resistance
3. Power frequency voltage withstand test for 1 minute.
03/12/16

This machine used for bending pressboard sheet which is
used to make cylinder. In this machine there are three roller,
one is movable and two are fixed. Pressboard sheet is put
between movable and fixed roller.
03/12/16

Chamfering is done on sheet before bending. Chamfering is
done in 100mm and
To prevent overlap when join the cylinder.
03/12/16

Blade saw machine cuts the Perm wood to make Base
block.
03/12/16

This machine is used to cut pressboard sheet. Up to 3.15mm thick
and 3000 mm width.
This machine max system pressure is 91 kg/cm².
03/12/16

This machine also used for cut pressboard sheet. This machine
system pressure is
Less than hydraulic shearing machine.
03/12/16

Power press machine is
used to make spacer.
(By use of die.)
Capacity: 10 mm
Thickness
R.P.M : 1440
03/12/16

• The Buchholz Relay is very important protective
device in oil filled Transformer.The BR saves the
transformer when there is major fault in active parts.
The body and the cap of our Buchholz Relay are made
of aluminium alloy casting making it low weight
and small in size without reducing the functionality of
the relay. Inspection windows, with graduated scale,
on both sides of the body , show the volume of the gas
collected inside the terminal box.The BR can work in
seismic vibrations area due to use of magnetic
switches. A gas release cock, a push button for
checking electric circuit are located on the top side of
the cap.
03/12/16

It detects the incipient faults much earlier
than is possible with other forms of
protection.
It is the simplest form of transformer
protection.
03/12/16

It can only be used for oil immersed
transformers equipped with conservator
tanks.
The relay is slow, minimum operating time
is 0.1 second and average time is 0.2
second. Such a slow relay is
unsatisfactory.
Buchholz relays are not provided for
transformers below 500 kVA. This is for
economical considerations.03/12/16

Setting of the mercury switch can not be
too sensitive otherwise there can be a
false operation by vibrations, earthquakes,
mechanical shocks to the pipe, sitting of
birds etc.
03/12/16

Most domestic consumers are equally
desirous of receiving a supply voltage at
all times of day and night which is high
enough to ensure satisfactory operation
of television sets, personal computer,
washing machines and the like but no
so high as to shorten the life of filament
lighting which is often the first
equipment to fail if the supply voltage
excessive.
03/12/16

In this situation, therefore and
despite the reservations concerning
the use of “TAP CHANGERS”.
Many of transformers with in the
public supply network must be
provided with on load TAP
CHANGER.
03/12/16

Transformer having ON-LOAD
TAP CHANGER are used in
provision of supplies to are
furnace, electrostatic plants,
chemical manufacturing process
& the like.
03/12/16

USER OF TAP
CHANGER
• Transformers user require tappings
for a number of reasons.
• To compensate for changes in the
applied voltage on bulk supply and
other system transformer.
03/12/16

• To compensate for regulation with in the
transformer and maintain the output
voltage on above types.
• On generator and inter-bus transformers
to assist in the control of system in VAR
flows.
• To allow for compensation for factors not
accurately known at the time of planning
on electrical system.
03/12/16

OFF LOAD TAP CHANGER
• The simplest arrangement is that
the transformer tappings are
terminated just below oil level and
changed by means of swinging
links or plugs mounted on a
suitable terminal board seperated
by an external handle.
03/12/16

ON LOAD TAP-CHANGER
• Whenever, voltage adjustment under
varying load condition is required the on
load tap changing transformer is used.
03/12/16

FABRICATION AND
TANKING
03/12/16

1.Good resistance to high electrical stress: High di-electric
strength. High gas absorption. No gas evolved under electrical
stress.
2.Good di-electric properties: Low dissipation factor. High
specific resistance.
3.Good stability against Oxidation: Longer Service life prevents
sludge and acid formation. Longer trouble free operation. Heat
Transfer not interfered due to non-sludging characteristics.
4.Low viscsity enable free circulation.
7.highflash point to eleminate fire risk and hazards.
8.Free from corrosive compounds.
9.Highly refined. Totally eliminates aromatic and sulphur
content.
10.Excellent thermal properties for efficient heat transfer and
cooling
03/12/16

TRANSFORMER NOISE
Understanding Transformer noise
Noise is defined as unwanted sound. But, what is
unwanted sound? A mellow sound to some can be
completely unacceptable to others. The difference then
between noise and sound is in the “ear of the hearer”.
Transformer “humming” has been known to soothe
people (which makes it a sound) but generally it is
thought to be a nuisance (which makes it a noise).
03/12/16

A transformer core is made from many sheets of special
steel. It is made this way to reduce losses and to reduce
the consequent heating effect. If the extensions and
contractions described above are taking place erratically
all over a sheet, and each sheet is behaving erratically
with respect to its neighbor, then you can get a picture of
a moving, writhing construction when it is excited. Of
course, these extensions are only small dimensionally,
and therefore cannot usually be seen by the naked eye.
They are, however, sufficient to cause a vibration, and
as a result noise.
03/12/16

The act of magnetization by applying a voltage to a
transformer produces a flux, or magnetic lines of force in
the core. The degree of flux will determine the amount of
magnetostriction (extensions and contra-ctions) and
hence, the noise level.
The obvious question is why not reduce the noise in the
core by reducing the amount of flux. Why? Because it is
not that simple.
03/12/16

Transformer voltages are fixed by system
requirements, and the amount of
magnetization, by the ratio of these
voltages to the number of turns in the
winding. The decision on what this ratio of
voltage to turns will be, is made for reasons,
mainly economic. It means that the amount
of flux at the normal voltage is invariably
fixed, thus setting the noise and vibration
level.
03/12/16

Noise Frequency
We have established that the transformer hum is caused
by the extension and contraction of the core laminations
when magnetized. Under alternating fluxes, we can
expect this extension and contraction to take place twice
during a normal voltage or current cycle. This means
that the transformer is vibrating at twice the frequency of
the supply, i.e. for 50 cycles per second supply
frequency, the noise or vibration is moving at 100 cycles
per second. This is called the fundamental noise
frequency.
03/12/16

Nothing in this world is ever perfect and so it is with
transformer cores. Since the core is not symmetrical and
the magnetic effects do not behave in a simple way, the
resultant noise is not pure in tone. We find from practical
work that transformer noise is made up of frequencies of
odd multiples of the fundamental known as 1st, 3rd, 5th
and 7th harmonics.
03/12/16

This means we get noise frequencies of 100 (1st), 300
(3rd), 500 (5th), 700 (7th) cycles per second. They are
not equally important for we find that the first and third
harmonics predominate and produce most of the
transformer sound.
It is important to know this because, with this knowledge,
we can measure the amount of noise at these
frequencies and determine whether amongst a number
of other noises, we really are picking up a transformer
noise.
03/12/16

Remember:
Noise is usually air borne.
Vibration is ground borne.
They are very much connected.
03/12/16

THANKYOU NOTE
We are very pleased and satisfied
with our entire 6 months learning
experience here at ECE industries.
This period has helped us attain a
high level and knowledge and has also
helped us in improving our overall
personality .This is where we would
like to thank Mr. H.S JOSHAN(Add.
Suppdt. Engineer,PSEB) for guiding us
and helping us to be a part of this03/12/16

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