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Table of Contents
Titles
1. 1.Introduction
2. Objective
2.1 Core assembly details
2.2 Coil assembly
2.3 Core and Coil assembly
2.4 Making connection
2.5 Top covering .
2.6 Tanking
1. INTRODUCTION
Transformer
A transformer is basically electromagnetic static equipment based on
the principle of Faradays law of electromagnetic induction. A transformer
essentially consists of a magnetic core, build up of insulated silicon steel
laminations, upon which are wound sets of coils suitably located with respect
to each other and termed as primary and secondary winding.
The working principle
If an alternating voltage is applied to the terminals of the primary winding of a transformer,
with the secondary winding open-circuited, a very small current will flow in the primary circuit
only, which serves to magnetize the core and to supply the iron loss of the transformer. Thus, an
alternating magnetic flux is established in the core which induces an emf in both primary and
secondary winding.The formula connecting induced voltage, flux and number of turns is:
V/N=BmxAnxf/22.51x102
V/N=volts per turn, which is the same for both windings
Bm =maximum flux density in the core in tesla.
An=net cross-sectional area of core in sq. cm.
F=supply frequency in Hz.
The productivity of the transformers produced based on the rated power measured in KVA
mainly depends up on proper design of processes. Among the activities deployed during
designing, assembly process takes vital role to get good transformer product achieving the
demand of the country. So this manual is intended for proper assembly of each and every parts of
the transformer and to take precaution during complete as well as semi assemblies.
2. OBJECTIVE
The target of the factory is producing as well as maintaining the transformers by
following clear cut procedures of assembly. So this manual is intended for all individuals
participated in assembly process to increase the productivity and providing good services
for the customers.
To mention some of those benefits:-
Using all the accessories needed for the product
To use appropriate tools
Durability of the product
Time management
To mitigate unnecessary check up after test
Providing knowledge and skills for works
2. ASSEMBLY
2.1 Core Assembly Details
Selection of core diameter
Based on the requirement of no-load loss and no-load curent , a suitable working flux density
is chosen. In some cases, the buyer also specifies the requirment of maximum flux density.
Once the number of turns and flux density are known, the gross core area may be calculated by
using the formula
Et=Phase voltage/Turns=4.44*f*Bm*Ag*0.97*10-4
Where, f is the rated frequency which is 50 Hz
Bm is the maximum flux density in tesla
Ag is the gross core area in sq. cm (to be calculated)
0.97 is the staking factor (assumed)
Once the gross area Ag is known, the approximate core diameter can be calculated by using the
following formula
Ag=k1*pi*d2/4
Where k1 is a factor to be selected on the basis of the number of core steps and d is the required
core diameter we are looking for.
The approximate vulue of k1 may be assumed as follows:
For 6 steps,the approximate value of k1=0.92
For 7 steps,the approximate value of k1=0.925
For 8 steps,the approximate value of k1=0.93
For 9 steps,the approximate value of k1=0.935
For 10 steps,the approximate value of k1=0.94
For 11 steps and above ,the approximate value of k1=0.945
Various type of core stacking for three-phase transformers has commonly been adapted during
manufacture. In designing core lamination the designer should look in to the applicability of the
scheme before going in to the final design.
The iron lamination that serves as the magnetic circuit can be constructed in different ways with
respect to the winding. The core-type, in which the iron forms a low reluctance path for the
magnetic flux set up by the voltage impressed on the primary. The core of the shell type consists
of two or more paths through which the flux divides.
The magnetic core is built up of laminations of high grade silicon sheet steel, which are
insulated from each other by special coating of varnish. The usual thickness of laminations is
0.18mm, 0.23mm, 0.27mm, 0.30mm, and 0.35mm.
Keep the core center and limb center to build the core sheet
Tie the bottom yoke by either metal or
wood frame
off to 58 turns
Primary phase voltage
No. of primary turns at normal = secondary phase voltage x sec. turns
15000
= 400/ 3 x 58 = 64.935 x 58
= 3766 T
Additional turns toward 5% tapping voltage = (3766 x 5)/100 = 188
Total primary turns = 3766 + 188 = 3954
2.2 A
the working current density is 0.95 sq mm = 2.315 A /sq mm
248
Axial length of HV coil 334.8 mm 24.2 mm
round of 335 mm 25 mm
As of now we have concluded that there is one coil per phase, having 3954 turns, the winding
length is 335 mm, the radial built of coil being 25 mm, and inter layer insulation 4 mil Kraft
paper.
400
Voltage per phase Vs = 3 = 231 v
100
Current per phase Is = 3 x 0.4 = 144.3 A
low voltage conductor, since the current is generally high, a rectangular conductor is commonly
used. Multiple strips in parallel are also selected for a higher rating transformer. The section of
the size of strips plays a very vital role on the performance of the transformer. In general, the
depth of a strip not be more than half of the strip width, and not less than 1:6. But for all practical
purpose we narrow down to 1: 4.
width
Therefore we may write, maximum ratio 2 and minimum ratio
depth
width
4
depth
In case a coil has been designed with more than one strip and if the strips are placed one above
the other, then the transposition is must. The purpose of transposing the strips is to make the
length of the strips almost similar, thereby making the resistances of both the strips equal.
1 1 1 2
2 2 2
1
(a) (b)
Schematic diagram of transposition
An Example: A coil is designed with two strips in parallel to share a total of 150 A. Each strip
should carry half of the total, i.e. 75A. In non transposed coil, because of unequal length and
unequal resistance, the strip placed below will draw more current (say 80A) because of its low
resistance, whereas the upper strip will draw less current (say 70 A) because of its high
resistance.
After Wind the Primry and the secondary windings correctly they are ready for core
coil assembly.
Fig.6 core with inserting coils Fig. 7 Describes active part Assembled or core and coil
Assembled
2. 4 Making connection
Fig.9 Delta connection of winding
3.1.3
3.1.4
Tap connection
3.1.5 Tapings are provided on the high voltage
winding for adjusting the winding turns in
accordance with the available incoming voltage.
3.1.6
2
3.1.14 3.1.15 2 3.1.16
2
-
3
3.1.17 3.1.18 3 3.1.19
3
-
4
3.1.20 3.1.21 4 3.1.22
4
-
5
3.1.23 3.1.24 5 3.1.25
5
-
6
3.1.26 3.1.27 3.1.28
3.1.31
Adjustment of tapping turns will offer a fairly constant secondery voltage at load.
There are five tapping positions for distribution transformer expressed as percentage of
high voltage which are:- +5% , +2.5% , N , -2.5%, -5% tap changer
plate
3.1.32
3.1.33
3.1.34
3.1.35
3.1.36
3.1.37
3.1.38
3.1.39
3.1.40
3.1.41
3.1.42
3.1.43
3.1.44
3.1.45
3.1.46
3.1.47
3.1.48
3.1.49
3.1.50
3.1.51
3.1.52
3.1.53
3.1.54
3.1.55
3.1.56
3.1.57
3.1.58 Fig.10 showing the tap changer
connection of a transformer
3.1.59
3.1.60
3.1.61
3.1.62
3.1.63
3.1.64
3.1.65 2.5 Top Covering
3.1.66
3.1.67
3.1.68
3.1.69
3.1.70
3.1.71 Fig.11 Describes
All parts with top
cover tank.
3.1.72
3.1.73
3.1.74 2.6 Tanking
3.1.75
3.1.76
3.1.77
3.1.78
3.1.79
3.1.80
3.1.81
3.1.82
3.1.83
3.1.84
3.1.85
3.1.86
3.1.87
3.1.88
3.1.89
3.1.90
3.1.91
3.1.92
3.1.93
3.1.94
3.1.95
3.1.96
3.1.97
3.1.98 Fig. 17 Describes final Assembled tank
3.1.99
3.1.100
3.1.102 Insulating oil is the mineral oil, which acts as a di-electric and coolant media in
transformers, should meet the long time uninterrupted service, which are the prime
requirements of the day.
3.1.103 Transformer oil is manufactured by refining of petroleum feed stocks which
obtained as first distillate under vacuum distillation of crude oil after taking out
lighter cuts like gasoline, keo sene diesel atmospheric pressure. Is characteristic
proper lies are much dependent or hydro carbon composition. These petroleum
products are compounded in to aromatic, naph the nie and paraffinic containing small
amount of polar compounds to carry out the function of di-electric and coolant media
in transformer oil must have certain specific properties, which can be classified,
physical, chemical and electrical categories.
3.1.104 Out of many characteristics which specified to evaluate the quality of transformer
oil, electrical properties and stability characteristics are important.
A) Electrical strength:- is the minimum electrical stress in KV that case a break down in the
insulating ability of the medium. It is very sensitive external impurities, particularly P(56,
Paralas)
3.1.106 Presence of moisture, metallic particle, fiber and are found to affect the electrical
strength drastically
B) Specific resistance:- it is the ratio of D.C potential radiant in volts per centimeter
paralleling the current flow with in the specimen in the current density in ampere per
square centimeter at a given instant of time under prescribed conditions and affected by
moisture and water.
C) Di-electric dissipation factory is the tangent of the angle (delta) by which the phase
difference b/n applied voltage and resulting current deviates from /2 radian when the
dielectric of the capacitor consists exclusively of the insulating oil.
3.1.108 In view of the longer time required to assess the behavior of insulating fluids in
the actual system, various types of accelerated tests have been developed.
3.1.109
a) Accelerating ageing test:- a known amount of oil (300ml) is taken in a beaker with
copper catalyst in the ratio of 0.0575 sq cm/g and aged at 115 oC for 96 hours. After
the stipulated period the samples are tested for electrical properties such as resistivity,
dissipation factor, acidity and the quantity of sludge.
b) Oxidation stability test. The hydro carbon easily under goes oxidation a part from
the external imparities, the oxidation products are the main cause of deter ration in the
quality of oil. In severe cases, the oil insoluble sludge is formed due to oxidation and
deposits on the core and windings and impairs the heat transfer characteristics.
3.1.110
3.1.111
3.1.112
3.1.113 Flash point
3.1.114 The temperature at which the oil gives off so much vapor that this vapor,
when mixed with oil, forms an ignitable mixture and gives a momentary flash on the
application of a small pilot flame under the prescribed condition of test.
3.1.115
3.1.116 Pour point
3.1.117 The lowest temperature expressed as a multiple of 3 oC at which the oil is
observed to flow when cooled and examined under prescribed condition.
3.1.118
3.1.119 Storage and handling
3.1.120 The right kind of storage, handling and transportation also increase the
reliability of the transformer oil.
3.1.121
3.1.122 Compatibility and contaminants
3.1.123
3.1.124 Transformer oil is compatible with insulating material used in a
transformer and care should be taken a bout compatibility with materials used in the
tanks. Line material l.e rubber gaskets etc. as the solubility of these products will
greatly affect the properties of the transformer oil when used for topping up.
3.1.125 Transformer oil properties may be deteriorate due to contamination
occurring during handling. Transportation, storage and during transformer operation.
Major contaminants could be water particles, chemical base oils or solvents possibly
corrective action to be taken to remove these contaminates.
3.1.126
3.1.127 A) Water
3.1.128 Water is the most contaminant in transformer oil during storage, handling
transport and operation, especially in humid climate.
3.1.129 B) particles
3.1.130 Suspended particles, together with water lower the breakdown voltage.
3.1.131
3.1.132 Oil Treating Method
3.1.133 Transformer oil properties may be deteriorate due to contamination due to
water and suspended particlesand chmical Inmurities . They must be avoided through
oil treatment.Free water can be drained off from the bottom of the tank or container.
Dissolved water can be removed by bubbling dry air or nitrogen at slightly elevated
temperature. The most suitable and recommended method is degassing by vacuum
filtration. Here the oil heated up to 65 to70 oC, vacuum treated and filtered through
particle filter. The particles can be simuntineusty removed by degrading through fine-
micron filter. By using Oil Treatment Machine we filtrate use and new transformer
Oil. After Treatment.
I. Electrical breakdown vlotage for new Untreated : 30KV, rms(min)
II. Electrical Breakdown voltage after flitation : 60KV, rms (min)
3.1.134
3.1.135
3.1.136 .
3.1.137
3.1.138
3.1.139
3.1.140
3.1.141
3.1.142
3.1.143
3.1.144
3.1.145
All transformers, whether power or distribution, are subjected to the following routine tests
after completing the manufacturing activities and prior to dispatch from the factory.
The tests are generally conducted as per IEC 60076.
For explaining the test circuits the transformer is taken as Dyn5 connected.
3.1.237
3.1.238
3.1.239
3.1.240 11. Testing parameter of transformer
3.1.241 11.1 Voltage ratio for 15 / 0.4 KV
3.1.294
3.1.295
3.1.296