The purpose of cooling fins is to increase the available contact surface area for cooling air. This purpose is served by ra conventional tors in transformers. However in hermetically sealed designs the cooling fin design also enables a degree of flexibility which is needed to accommodate the expansion and contraction of the oil. rere jransformers convert electrical [ energy from one voltage level to another. They are an essential part of the electricity network. After generation in power stations, electrical energy needs to be transported to the areas where it is consumed. This transport is more efficient at higher voltages. Therefore power generated at 10 -30 KV is converted by transformer into typical voltages of 220kV up to 400kV, or even higher. Since the majority of electrical installations operate at lower voltages, the high voltage nceds to be converted back close to the point of use. Electricity Distribution Company usually provides supply at higher voltages to larger electricity users such as factories, mines, shopping centers, hospitals, etc. This enables users to ‘operate any specialized equipment requiring higher voltages. In most cases voltage must still be stepped down to 415/240V for general use, so the owners of the premises in effect take over the last stage in the electricity distribution task, using their own transformers located on site, These are called “private transformers” as distinct from “utility transformers” In this way, electrical energy passes through an average of four transformation stages before being consumed. A large number of transformers of different classes and sizes are needed in the transinission and distribution systems, with a wide range of operating voltages. The last transformation step into the consumer mains voltage is done by the distribution transformer. In Indian scenario power sector reforms have led to improvement in reduction of ‘T&D losses in the network. ‘Typically. a third of losses occur in transformers, and two thirds in the rest of the system. Distribution transformers represent the 2nd largest loss component in the networ This paper addresses the potential for high efficiency distribution transformers, as technology to improve network losses and PML also impart higher reliability in the system. Superior technology of Distribution transformers The construction of transformer consists of two active components: the ferromagnetic core and the windings. The core and windings together are normally referred to as the “active part”, The passive part of a transformer is the cooling system, consisting of the tank & the oil. Let us look at each component of the transformer in detail. Core: The cutting of the core sheets and the material of the ferromagnetic core are optimized according to the desired no-load characteristics and the specified noise level. Extensive rationalization of the shape and the clamping device enables us to produce a core with minimum losses and dimensions. This methodology optimizes the consumption of both materials and energy, bringing benefits to the user, the environment and the ‘manufacturer. ‘The core has to be constructed in such a way as to limit the energy losses ‘caused by eddy currents and hysterisis to a minimum. This is possible by use of silicon steel, a special soft steel with a 3.5% silicon content, which is characterized by low hysterisis losses and high resistivity. The core consists of a series of thin sheets of tiple overt ap stacking pattern Electrical india w February 2009 55PTE ALT LILLE ELLs} cold rolled grain oriented silicon steel insulated on both sides by an oxide layer. Conventional grain oriented ste] (Grade MS or M4) is used with normal no-load loss characteristics, while transformers with reduced no load losses are built using HiB steel (Grades MoH, ZDKH, etc) which are usually laser treated. These sheet steels are 0.30mm, 0.27mm or 0.23mm thick. Extremely low no load losses can be achieved only by using wound cores made of amorphous metal. This has highly specific properties e.g. very low thickness of 0.025mm, low stacking factor of 0.86, low saturation level of 1.5 tesla and therefore requires a specially adapted design. The basic amorphous material require proper handling during manufacture of cores and core coil assembly as it is sensitive to mechanical stresses. ‘Moreover due to basic winding shape being rectangular the design should take care of high mechanical forces during the short circuit. Minimum — magnetic flux distortion in the transition areas between yokes and core legs is possible by optimizing the cut of the core sheets and the stacking pattern. The core sheets when they are cut at an angle of 45°, allow maximum flow of magnetic flux in the rolling direction. This is extremely important because losses in grain-oriented magnetic steel are smallest in the direction of rolling, Also the sheets are stacked in an overlap pattern of either single or multiple overlaps. The multiple overlap or step-lap method offers additional benefits of lower no load losses & noise levels. Step lap cores are preferably made on fully automatic cutting and stacking machines. Once the sheets are stacked the BRR 55 1 Feary 20091 electrical nda core is compressed and glued to for a dlosely bonded core. This also helps to reduce noise levels. Another unique feature of the core is to have an oval-shaped core section, formed by combining the traditional stepped and fully filled round shape with rectangular mid section. This gives great flexibility in the height to which the steel sheets can be stacked, thus allowing the ideal cross-section to be made for any design, while maintaining the use of standard materials and dimensions. This method combines the benefits of rectangular core section (simplicity of production) with those of a round core section (excellent short circuit withstand capability of | the windings). Clamping Device: Use of simple profiled steel yoke clamping system and a number of metal tensioning bands eliminates the need for either yoke bolts ( which distort the magnetic flux) or tie rods between the upper & lower yoke clamps. Low Voltage windings: These ‘windings are usually made of copper or aluminum sheet conductor (foil). In this type of winding any high voltage ampere turn asymmetry which might ‘occur is compensated automatically by an appropriate internal current distribution in the low voltage foil This reduces the axial stresses produced by short circuits to a minimum (down to 10% of those for conventional windings), thus enabling the axial support construction to be greatly simplified. Foil windings have following, other benefits: + greater simplicity in fitting cooling ducts. * more even heat distribution through the windings. + Automatic winding techniques can be used, + Low eddy losses. ‘The maximum voltage between each turn is only a few volts. This allows the insulation needed between the turns (foils) to be limited to 1 or 2 sheets of fine Kraft paper only a few hundredths of a millimeter thick. This insulation is coated with a thermo- setting epoxy adhesive which cures and. ‘bonds during the drying process. ‘The structures forming the HV-LV gap are fitted directly onto the low- voltage foil winding, thus forming a part of it. These processes all enhance the transformer’s short circuit withstand capability. High Voltage Windings: These are oflayer type. The copper oraluminum conductors are made of one or more round or rectangular wires, either with an insulating enamel or wrapped in insulating paper. The main benefits of layered windings are: + They form a simple winding which allows a continuous or semi automatic winding. + The impulse voltage distribution throughout the winding is predictable and controlled. + Axial cooling ducts are simple to build and fit. + Any taps required can be brought out anywhere in the winding through the layers. oePIAL MLE CE ‘The insulation between the layers consists of special diamond pattern of epoxy adhesive coated Kraft paper which cures during the drying process, bonding the windings into a single structure, The high voltage winding is wound directly onto the low voltage winding, over the structures forming the main gap, giving maximum mechanical strength, rigidity & compactness. This mechanical strength is very important since in the eventof short circuit, the windings have to sustain very high radial forces. ‘The mechanical effect of these forces Low vortage windin High voltage winding GE 58.0) February 2009 u Electrical india is minimal in round windings, since these windings inherently have the ideal form to withstand radial stresses. ‘The mechanical effect is very high in rectangular windings. In order to combine the advantages of a rectangular cross-section with the benefits of round windings the unique concept of oval shaped cores and windings has been developed. Assembly of cores and windings: ‘The E-shaped cores and the windings are transferred from their various workstations to the assembly area. The windings are pushed over the core legs and wedged up to fill the spaces between the core and winding as much as possible. The magnetic circuit is then completed by interleaving the laminations of the upper yoke with the laminations of the core legs. Bushings are mounted on the cover, which is then fixed onto the assembled active part. The next step consists of connecting the windings to the bushings. Transformers are fitted with an off circuit tap changer which is either controlled by cable or by a drive shaft. ‘The core and winding assembly is dried for a specific time in an oven to remove the moisture from the insulating materials. This time depends on the quantity of insulating materials, which in turn depends on the transformer’s rating and voltages. Tank: Worldwide majority of distribution transformers tanks are constructed with cooling fins. There is limited demand for panel radiator types. The purpose of cooling fins is to increase the available contact surface area for cooling air. This Purpose is served by radiators in conventional transformers. However in hermetically sealed designs the cooling fin design alsq enables a degree of flexibility which is needed to accommodate the expansion and contraction of the oil as it heats and cools, due to load and ambient temperature. This allows the tank to be totally filled (and hermetically sealed), with the clear benefit of prolonging the transformer’s life expectancy and reducing maintenance. Hermetically sealed transformers offer major advantages compared with transformers fitted with a conservator: + The oil cannot come into contact with the air, thus ensuring preservation of its dielectric integrity. + Reduced maintenance, eg. no checking required if silica gel breather, no need to monitor for water ingress + They occupy smaller space, leaving more room — for connections in compact installations. ‘The construction of these tanks is extremely simple. The bottom, top frame, corrugated fin wall panels and plain wall panels are mounted on specially designed welding tables and welded together. The skill andcraftsmanship of highly experienced welders and leak tests during production ensure leak free finished tanks. The reliability of these tanks is, proven by stringent fatigue and over pressure tests carried out on transformers of this type. These tanks Mounting of active part in tank & oll crn ae ULC ULE are subjected to expansion- contraction cycles which simulate the mechanical load on a tank over its service life. ‘Mounting of active part in tank & oil filling: Once the active part has been dried in the oven, it is placed inside the tank. The top cover is then bolted or welded onto the tank as specified by customer. Both sealing methods are equally effective. The transformers are placed in a vacuum chamber and filled with pre-treated oil (filtered, dried and degassed) under full vacuum. This ensures complete impregnation of the insulation materials by the oi, giving the insulation structure maximum dielectric strength. After a specific stabilization period the transformer is subjected to tests as specified in standards. Conclusion In India the failures of distribution transformers is alarming, It is necessary that we take into consideration the technological advances made globally and introduce new technologies in distribution transformers in our country. With the advantages of hermetically sealed transformers. mentioned above it becomes absolutely necessary that we adoptthis technology. Thistechnology willzesult inmore eliabletransformer as this technology helps in reduction of mechanical and voltage stresses on insulation, Also transient over voltages are reduced, Moreover with this technology we can have energy efficient transformers with low losses and optimum use of materials. ™ TT As Bhatia. Deputy General Manager Design and Technology, Crompton ‘Greaves Limited DIGITAL MULTIFUNCTION AND INSULATION CONTINUITY VOLTAGE TESTER DIGITAL INSULATION RESISTANCE aps ais MODEL KM 1152 MF FEATURES ‘* Polarization Index (Pl) on 250, 500 and 1000V '* Dielectric Absorption Ratio (DAR) ‘on 250,500 and 1000V ‘ Insulation measurement from 2k® (250V range) to 8G.2(1kV Range) + Leads Auto-Null key ‘* DC Voltmeter from #1VDC to + 950VDC © AC Voltmeter from 1 Vac to 700 Vac * Gas Arrester Function Ceara GRUB 601 etary 2009 lect Inca FEATURES : ‘* Microprocessor Controlled... DIGITAL HIGH VOLTAGE INSULATION TESTER With Polarization Index and Dielectric Absorption Ratio. KM 6213BIN ‘= Variable H. V. 500V-10kV in Steps of SOOV. ‘* Maximum Insulation Resistance(10kV) 600GQ. ‘* Works with Rechargeable Battery, adaptor ‘supplied with instrument. ‘* Polarization Index R@10Min | R@1Min '* Dielectric Absorption Ratio R@1Min / R@30sec ‘* Resistance per Voltage 25G/500V ‘ Automatic Voltage Discharge Circuit. T.J.Road, Sewree (W), MUMBAI- 400 015. ee Pe On Pee ear ee ee ee ea Prac) Cee eal