DISTRIBUTION TRANSFORMER DRY OVEN

The drying

time of distribution transformer core winding

assembly at T.R.W workshop is presently

based on the high voltage rating.It is normal practise to dry out the

transformer core-winding assembly for twenty-four hours for 11 KV distribution transformers and thirty-six hours for 33 KV transformers irrespective of the capacity.This has been decided during drying process.

considering the total capacity of transformers placed in oven

COREWINDINGASSEMBLYFOROVENING

OVEN

Drying out of transformer corewinding assembly is an extremely important aspect in

transformer manufacturing.This should be done in order to remove moisture fromcore winding assembly.It is required that temp inside oven should be kept at defined value throughout the drying process in order to get complete bonding between windings and insulationandtoremovethemoistureinsidecorewindingassembly. Sincemoistureevaporatesover100degree,theoventemperatureissetbetween112degreeto 120 degree centigrade.It is heated up to temp above ambient temp before loading the transformercoreassemblies

TRANSFORMERTANKING

Tankingmeansassemblingthecorecoilassembliesjobintotransformertankwith

allnecessaryaccessories.
All tanks are made of high quality steel and can withstand vaccum as specified by the international standards and the customer. All welds are tested, ensuring 100% leak proof of seams and mechanical strength. All transformer tanks are given a smooth finishing by using the "SHOT BLASTING" process.

PAINTINGANDFINISHING

The entire procedure of painting is done

under two stages: 1. Cleaning of tanks The cleaning of tank is done normally by chipping/grinding. The outside surface of the tank is short blasted to achieve a very fine and smooth finish. 2. Painting of tanks After cleaning the tanks, a coat of hot oil resistence paint is applied on the internal surface of the tank. The outside surface is painted with a coat of Red Oxide primer and subsequently with one coat of enamel paint as per customer's requirement. Fittings and accessories as per customer's specification and drawing are checked. Air Pressure test is subjected to avoid any leakage and seepage on all transformer.Transformers are filled with oil upto the minimum level marking, wherever necessary.

Core-Coil Assembly
The components produced in the coil winding and core assembly stage are then taken into core-coil assembly stage. The core assembly is vertically placed with the foot plate touching the ground. the top yoke of the core is removed. The limbs of the core are tightly wrapped with cotton tape and then varnished. Cylinder made out of insulating press board/ pressphan paper is wrapped on all the three limbs. Low Voltage Coil is placed on the insulated core limbs. Insulating block of specified thickness and number are placed both at the top and bottom of the L.V.Coil. Cylinder made out of corrugated paper or plain cylinder with oil ducts are provided over L.V.Coil. H.V. Coils are placed over the cylinder. Gap between each section of H.V. Coils including top & bottom clearances is maintained with the help of oil ducts, as per the design/drawings.

COREASSEMBLY
The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO) Silicon Steel It is in the form of thin sheets & cut to size as per design. Generally three different shapes of core laminations are used in one assembly. Notching is performed to increase the magnetic path. The laminations are put through annealing process. These laminations are assembled in such a manner that there is no air gap between the joints of two consecutive sheets. The entire assembly is done on a frame commonly known as core channel. These frames being used as a clamping support of the core assembly.

coilwindingisoftwotypes

COILWINDING

1. High Voltage Coils: H.V. Coils are the components of finished transformers. They are made on automatic layer setting winding machines. A solid cylindrical former of predetermined diameter and length is being used as hase over which is made. Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as basic raw material. The coils are made in number of layers. The starting and finishing leads of each coil are terminated on either side of the coil. These leads are properly sleeved and locked at number of points.

2. Low Voltage Coils: L.V. Coils are also one of the components of transformer. The procedure of making low voltage coil is generally same as described earlier. The shape of the basic raw-material (Al or Cu) is rectangular. The Test: The "Turn Test" is carried out on the H.V. Coils as per the specifications.

MANUFACTURINGPROCESSOF DISTRIBUTIONTRANSFORMER

PROCESS FLOW :

TRANSFORMEROIL
Transformeroilorinsulatingoilisusuallyahighlyrefinedmineraloilthatisstable athightemperaturesandhasexcellentelectricalinsulatingproperties.Itisusedinoil filledtransformers,sometypesofhighvoltagecapacitors,fluorescentlampballasts, andsometypesofhighvoltage switches and circuitbreakers.Itsfunctionsareto insulate,suppresscoronaandarcing,andtoserveasacoolant. Theoilhelpscoolthetransformer.Becauseitalsoprovidespartofthe electrical insulation between internal live parts, transformer oil must remain stable at high temperaturesforanextendedperiod.Toimprovecoolingoflargepowertransformers, theoilfilledtankmayhaveexternal radiators throughwhichtheoilcirculatesby natural convection. Very large or highpower transformers (with capacities of thousandsofKVA)mayalsohavecoolingfans,oilpumps,andevenoiltowaterheat exchangers. Large,highvoltagetransformersundergoprolongeddryingprocesses,usingelectrical selfheating,theapplicationofavacuum,orbothtoensurethatthetransformeris completelyfreeofwatervaporbeforethecoolingoilisintroduced.Thishelpsprevent coronaformationandsubsequentelectricalbreakdownunderload. Oilfilledtransformerswithaconservator(anoiltankabovethetransformer)tendto beequippedwithBuchholzrelays.Thesearesafetydevicesthatdetectthebuildupof gases(suchasacetylene)insidethetransformer(asideeffectofcoronaoranelectric arcinthewindings)andswitchoffthetransformer. Breatherisusedforoilfilling mineraloilofpaleyellowcolour isused

TESTING OF TRANSFORMER
TESTING IS CARRIED OUT AS PER IS-2026. ROUTINE , TYPE TESTS & SPECIAL TESTS

ROUTINE TESTS ( TO BE CARRIED OUT ON EACH JOB) 1.Measurement of winding resistance 2.Measurement of insulation resistance 3.Seperate source voltage withstand test (High Voltage test on HV ) 4.Induced Over voltage Withstand test (DVDF test) 5.Measurement of voltage ratio 6.Measurement of NO LOAD LOSS & current. 7.Oil BDV test.

ROUTINE TESTS
.Measurement of insulation resistance
Measures the insulation resistance of HV & LV windings with respect to earth (body) and between LV & HV winding. INSULATION TESTER OR MEGGER IS USED. Recommended Values are 2000Mohms for HV & 500 Mohms for LV.

MEGGER

INSULATION VALUES TEMP(in 20 30 degree

RESISTANCE
40
200M.ohm

50
100M.ohm

60
50M.ohm

200M.ohm 400M.ohm

100M.ohm 200 M.ohm

50M.ohm 100M.ohm

25M.ohm 50M.ohm

TTR(TRANSFORMER RATIO TEST)

TURNS

T.T.R test measuresthe turn ratio and exciting current of windings in in one or both windings or magnetic core circuit. should not be more than 1% i.e not more than 44.440 and not less than43.560

distribution transformers.Deviations in turns ratio readings indicate problems T.T.R of H.T winding/L.T winding of Transformer

The TTR set operates on principle that voltage ratio of transformer at no load is equal to true turns ratio . The major source of error in a transformer is a primary impedance drop due to magnetising current,which is kept to minimum by excitation at fraction of

rated voltage.By employing a design that meets both these conditions along with null balance system,the turns ratio of distribution transformer is detemined accurately.

D.V.D.FTEST
Induced Over voltage Withstand test (DVDF test)- This test checks the inter turn insulation.

For a 11KV/433V transformer,866 Volts are applied at the 433V winding with the help of a Generator for 1 minute. This induces 22KV on 11KV side. The frequency of the 866V supply is also increased to 100HZ. Equipment used : MOTOR GENERATOR SET frequency is doubled by using motor generator set.8 pole induction motor is connected to 4 pole generator.as speed is inversely propotional to no of poles.so speed become double Exciter is also connected to generator for producing double output voltage.