Summer Training

on manufacturing of
Transformers in Moon Light
Industries

Prepared by:

Abhishek Singh(14304)

Elect.Engg.Dept.
Kamla Nehru Institute of
Technology, Sultanpur

Introduction
Core material:
Basic material are Alloy Steel having main

content Silicon & carbon

Which increases permeability & reduces losses
Hot rolled
steel(HRS)

steel
Cold rolled
grain oriented
steel(CRGOS)

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

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:

45
2) 33 /55 overlapping
In 3- Shell type transformer middle
winding is reversed
If not then 73% more core is used which
leads in increase in over all cost
1)

Transformer winding

Spiral

Winding

Concentri
c

Helical

Cross-over

Sandwich

Continuou
s disc

Shell

Concentric

Sandwich

Spiral: It is used 100 A&

for low Voltage Winding

Mechanically very strong

Helical :Intermediate range

of current
Suitable for LV winding

of large transformer

Cross-over: suitable of

current not exceeding 20 A

Use for HV winding of

small transformer

Continuous disc: no of

turns wound radially over

one another

Sandwich: mostly used for

shell type transformer

Control leakage reactance

separated by spacers

HV & LV are near so

HV winding

leakage flux is reduced

mmf of each section is
same.

Mechanically strong

Insulations
Two 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 strength
2. Minor Insulation:
Insulation between
individual turns & between layers
Conductor Insulation: paper&cotton
Air insulated Transformer
insulation used is glass tap

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

Tapping
Main two location:
1. Inside Tank
2. Outside Tank
Considered as integral part of transformer

Tapping
operation
(1)On
load
tap
change
r

(2)Off
load
tap
chang
er

Tapping is terminated just bellow oil level

External handle
Taping is done on HV winding
Provided in middle (axial & radial force)

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 contracts, air from

atmosphere enters in Conservator .

Risk of contamination of oil in transformer
Breather valve is mounted to avoid

moisture
Breather contain silica in it

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

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 slugging
To overcome this, synthetic oil is preferred
One of the e.g. is Chlorinated diphenyl is a

synthetic oil its permittivity is 4.5

WINDING SHOP
TYPES OF WINDING
NORMAL WINDING
ii. INTERLEAVE WINDING
iii. TERITARY WINDING
i.

ROTARY
HORIZONTAL

HELICAL

MACHINES
VERTICAL

CONTINUOUS
DISC

KTRANSPOSITION
TYPE

End Rings & shielding for prevention purpose

Conductor Insulation:
Precompressed press board insulation(CRIP
PAPER)
2. Craft paper
3. Also spacers as insulation
1.

Moisture Control
Winding Auto Clave: Uses temp. of 110 C
to 130 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

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

FINAL ASSEMBLY
Installation of active part and assembly of

accessories
TRANSFORMER TANK

BELL TYPE

JOINED AT
BOTTOM
SIDE

CONVECTIONAL
TYPE

JOINED AT
UPPER
SIDE

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 gauge): 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.
2.

Radiators
Thermosiphon

Method of Cooling:
For very high temp using HEAT
EXCHANGER

i.

CT(Current Transformer):Two
purposes;
1.
2.

Winding temp indicator (WTI)

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

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.

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

FINAL TESTING
ROUTINE TESTS

TYPE TESTS

NO LOAD TETS

TEMPRETURE
TEST

LOAD LOSS
INSULATION
TEST

IMPULSE TEST

ZERO
SEQUENCE
IMPEDANCE
TEST

CAPACITANCE &
TAN

SEPARATE
SOURCE

INDUCED OVER
VOLTAGE

WINDING TEST

VOLTAGE RATIO

HARMONIC AND
NOISE LEVEL
TEST

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

PRIMARY
CONDUCTOR

ASSEMBLY OF
SECONDARY

PRESSING &
TANKING

MOISTURE
CONTROL(72HRS
OR 168HRS)

VACUUMING(80C
)

TAN
MEASURMENT

ASSEMBLY OF
PORCELAIN
INSULATOR

OIL & QUARTZ

FILLING

Thank You