Documente Academic
Documente Profesional
Documente Cultură
of Technology (MANIT)
Pranay
Vijayvargiya
AGM (IT)
B.Tech
(2nd Year)
MANIT,
BHOPAL
ACKNOWLEDGEMENT
I would like to thank my project co-coordinator Dr. Mukesh
Arora, for providing all the materials possible and encouraging
me throughout the course. It is a great pleasure to
acknowledge the assistance and contributions of all the
engineers of TRM department, BHEL BHOPAL for their prompt
and timely help in the official clearances and valuable
suggestions during the time of this training. I would also like to
express my profound gratitude to TRM DEPARTMENT for
constant and valuable suggestions while doing the training
work.
Pranay Vijayvargiya
B.Tech (2nd Year)
MANIT, BHOPAL
CERTIFICATE
This is to certify that Pranay Vijayvargiya, student of
B.Tech 2nd year from MANIT, Bhopal has completed his
Vocational Training at BHEL, Bhopal from 2nd May, 2013
to 12th June, 2013.
PROJECT GUIDE
Dr. Mukesh Arora
AGM (IT), BHEL BHOPAL
DECLARATION
I, J .Ravi Kiran declare this training report submitted by
me an original piece of work aimed towards the partial
fulfillment of my B.Tech (Electrical Engineering)
graduate program, under the guidance of Dr. Mukesh
Arora (DGM), TRM division BHEL, Bhopal.
Pranay Vijayvargiya
B.Tech (2nd Year)
MANIT, Bhopal
BHEL - AN INTRODUCTION
Bharat Heavy Electricals Limited is a name recognized
across the industrial world. BHEL ranks among top 12 leading
international companies in power field and it is largest
engineering and manufacturing enterprises of its kind in India.
Established in late 50s, the company provides products
systems and service in the field of power generation,
transmission and utilization. Non conventional energy sources,
industry, transportation, oil, gas exploration &
telecommunication. BHEL has 14 manufacturing divisions & 4
power sector regional centers & 18 regional offices & a large no
of project sites spread all over India & 45 countries. Its export
ranges from individual products to turnkey power plants &
consultancy services. All major manufacturing erection &
service unit of BHEL have been awarded ISO 9000
certification.
BHEL Bhopal plant is the oldest unit of company. The product
range al Bhopal includes hydro, steam , marine & gas nuclear
turbines, hydro & turbo generators, transformers,
transportation equipments , capacitors , bushings , electrical
motors , rectifiers , oil rig equipments , switch gear & control
gears.
MAJOR CUSTOMERS OF
B.H.E.L
Supplied to all major utilities in India :
National Thermal Power Corporation (NTPC)
PGCIL
NJPC
NHPC
NLC
NPCIL
NEEPCO
APTRANSCO
APGENCO
JPPCL
ALL State Electricity Boards (SEBs)
Abroad:
TNB, Malaysia
PPC, Greece
MEW, Oman
OCC, Oman
GECOL, Libya
Trinidad & Tobago
CONTENTS
S. No.
1.
NAME OF ASSEMBLY:INTRODUCTION
2.
3.
4.
WINDINGS
5.
COIL ASSEMBLY
6.
POWER ASSEMBLY
7.
TECHNICAL DEVELOPEMENT
8.
INSTRUMENT
INTRODUCTION
A transformer is 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.
If a load is connected to the secondary, an electric current will
flow in the secondary winding and electrical energy will be
transferred from the primary circuit through the transformer to
the load. In an ideal transformer, the induced voltage in the
secondary winding (Vs) is in proportion to the primary voltage
(Vp), and is given by the ratio of the number of turns in the
secondary (Ns) to the number of turns in the primary (Np) as
follows:
BASIC PRINCIPLE
The transformer is based on two principles: first, that
an electric current can produce a magnetic
field (electromagnetism), and, second that a changing
magnetic field within a coil of wire induces a voltage across the
ends of the coil (electromagnetic induction). Changing the
current in the primary coil changes the magnetic flux that is
developed. The changing magnetic flux induces a voltage in the
secondary coil.
ENERGY LOSSES
An ideal transformer would have no energy losses, and would
be 100% efficient. In practical transformers, energy is
dissipated in the windings, core, and surrounding structures.
Larger transformers are generally more efficient, and those
Winding Resistance
Current flowing through the windings causes resistive
heating of the conductors. At higher frequencies,skin
effect and proximity effect create additional winding resistance
and losses.
Hysteresis Losses
Magnetostriction
Magnetic flux in a ferromagnetic material, such as the core,
causes it to physically expand and contract slightly with each
cycle of the magnetic field, an effect known
as Magnetostriction. This produces the buzzing sound
commonly associated with transformers that can cause losses
due to frictional heating. This buzzing is particularly familiar
from low-frequency (50 Hz or 60 Hz) mains hum, and highfrequency (15,734 Hz (NTSC) or 15,625 Hz (PAL)) CRT noise.
Mechanical Losses
In addition to magnetostriction, the alternating magnetic field
causes fluctuating forces between the primary and secondary
windings. These incite vibrations within nearby metalwork,
adding to the buzzing noise and consuming a small amount of
power.
Stray Losses
Leakage inductance is by itself largely lossless, since energy
supplied to its magnetic fields is returned to the supply with the
next half-cycle. However, any leakage flux that intercepts
nearby conductive materials such as the transformer's support
structure will give rise to eddy currents and be converted to
heat. There are also radiative losses due to the oscillating
magnetic field but these are usually small.
CLASSIFICATION OF TRANSFORMERS
1. According to method of cooling
a. Self-aircooled (dry type)
b. Air-blastcooled (dry type)
c. Liquid-immersed, self-cooled
d. Oil-immersed, combination self-cooled and air-blast
e. Oil-immersed, water-cooled
f. Oil-immersed, forced-oilcooled
g. Oil-immersed, combination self-cooled and watercooled
2. According to insulation between windings
a. Windings insulated from each other
b. Autotransformers
3. According to number of phases
a. Single-phase
b. Polyphase
4. According to method of mounting
a. Pole and platform
b. Subway
c. Vault
d. Special
5. According to purpose
a. Constant-voltage
b. Variable-voltage
c. Current
d. Constant-current
6. According to service
a. Large power
b. Distribution
c. Small power
d. Sign lighting
e. Control and signaling
CORE
Laminated transformer core
INSULATION SHOP
The service life of a distribution transformer is governed by the
condition of the insulating material. Deterioration of the
transformer insulating material reduces the dielectric strength
and also reduces the ability of the transformer to withstand
short-circuit
events.
Korea's
domestic
transformer
manufacturers use varnish to improve winding mechanical
strength. However, the solidified varnish deteriorates over time,
which adversely affects the characteristics of the transformers.
By improving insulation performance and the short-circuit
withstand strength of distribution transformers, the cost of
maintaining and replacing these transformers can be reduced.
Many pole-type transformer failures could be avoided by using
a hybrid insulation, where layers of aramid papers and cellulose
papers are used. Additional design modifications include
reducing the number of cooling ducts between layers and
reinforcing the frame of the transformer to improve short-circuit
withstand strength. Then, varnish impregnating process is not
required when this hybrid insulation is used. The higher
reliability and longer life anticipated of hybrid-insulation
manufactured transformers should result in cost savings to the
utility. Construction of oil-filled transformers requires that the
insulation covering the windings be thoroughly dried before the
oil is introduced. There are several different methods of drying.
Common for all is that they are carried out in vacuum
environment. The vacuum makes it difficult to transfer energy
(heat) to the insulation. For this there are several different
methods. The traditional drying is done by circulating hot air
over the active part and cycle this with periods of vacuum (hotair vacuum drying, HAV). More common for larger transformers
is to use evaporated solvent which condenses on the colder
active part. The benefit is that the entire process can be carried
out at lower pressure and without influence of added oxygen.
This process is commonly called vapour-phase drying (VPD). For
Process of VPD
Basic Equipment of Vapor Phase Drying (VPD) plant:
a. Evaporator system.
b. Condensation system.
c. Autoclave.
d. Vacuum system.
e. Solvent Pumping system.
f. Heating system for evaporator and autoclave.
g. Heat recovery system.
h. Distillation equipment.
i. Special water extraction measuring equipment.
j. Computer aided process.
The whole process is carried out in % stages, which is as
explained below:
R1: Preparation:
In this first stage, the oven is prepared for the process. The job
is let inside the chamber by means of crane. All the instruments
and devices are checked for correct operation. The oil filling
pipe is placed in position. Thermocouple is attached to the core
of the transformer for temperature monitoring; drain plug is
connected by steel pipe, etc... Finally, the door is closed and
clamped by hydraulic pump.
H1: Heating Up:
The heating process is started after initial preparation. Pressure
of 7mBar is maintained within the autoclave. The capacity of
solvent tank is 12,000 L and a minimum of 5,000-6,000L is
maintained during the process. The heating cycle is of 48-60
WINDINGS
The conducting material used for the windings depends upon
the application, but in all cases the individual turns must be
electrically insulated from each other to ensure that the current
travels throughout every turn. For small power and signal
transformers, in which currents are low and the potential
difference between adjacent turns is small, the coils are often
wound from enameled magnet wire, such as Formvar wire.
Larger power transformers operating at high voltages may be
wound with copper rectangular strip conductors insulated by
oil-impregnated paper and blocks of pressboard.
Highfrequency transformers operating in the tens to hundreds of
kilohertz often have windings made of braided Litz wire to
minimize the skin-effect and proximity effect losses. Large
power transformers use multiple-stranded conductors as well,
since even at low power frequencies non-uniform distribution of
current would otherwise exist in high-current windings. [62] Each
strand is individually insulated, and the strands are arranged so
that at certain points in the winding, or throughout the whole
winding, each portion occupies different relative positions in the
complete conductor. The transposition equalizes the current
flowing in each strand of the conductor, and reduces eddy
current losses in the winding itself. The stranded conductor is
also more flexible than a solid conductor of similar size, aiding
manufacture. For signal transformers, the windings may be
arranged in a way to minimize leakage inductance and stray
capacitance to improve high-frequency response. This can be
done by splitting up each coil into sections, and those sections
placed in layers between the sections of the other winding. This
is known as a stacked type or interleaved winding.Both the
primary and secondary windings on power transformers may
have external connections, called taps, to intermediate points
on the winding to allow selection of the voltage ratio.
In distribution transformers the taps may be connected to an
automatic on-load tap changer for voltage regulation of
COIL ASSEMBLY
Winding design and manufacturing practices for power and
distribution transformers has focused in the differences
between rectangular core and coils and layer windings common
in the production of distribution transformers and disc and
helical windings and circular core designs common in power
transformers. In the small power transformer market defined as
5-15 MVA, ONAN, with primary winding voltages up through 69
kV class, both core and coil designs arecommercially available.
Rectangular core and coils and layer windings offer the
advantage of lower costs for manufacturing compared to power
class circular core and coils with disc and helical windings.
Distribution transformers are applied at lower voltages, ratings
stated in KVA, lower short circuit and thermal duties serving
residential and commercial loads. Power transformers are
applied atvoltages from 15 kV to 765 kV and higher, ratings
stated in MVA, short circuit duties are high, thermal loading
variable and in some cases severe. Generator Step-up
transformers, unit auxiliary transformers, multiple winding
transformers, autotransformers, transmission and distribution
bulk power substation service with and without load tap
changing all must be designed to withstand the rigorous duty
for these power class transformer applications.
ground and the top yoke is removed. The limbs of the core are
tightly wrapped with cotton tape and then varnished during the
manufacturing and even repairing process.
First, the individual windings are assembled one over the
other to form the entire phase assembly.
The radial gaps between the windings are subdivided by
means of solid transformer board barriers.
Stress rings and angle rings are placed on top and bottom of
the windings to achieve a contoured end insulation design
for optimal control of the oil gaps and creepage stresses.
The complete phase assemblies are then carefully lowered
over the separate core legs and solidly packed towards the
core to assure optimal short circuit capability.
The top core yoke is then repacked and the complete core
and coil assembly is clamped.
The lead exits (if applicable) and the lead supports and
beams are installed. All winding connections and tap lead
connections to the tap changer(s) are made before drying
the complete core and coil assembly in the vapor phase
oven.
PROCESSING OF CORE AND COIL ASSEMBLY
The completed core and coil assembly is thoroughly dried to
pre-determined power factor readings by the vapor phase
drying process , providing the fastest, most efficient and most
effective drying of the transformer insulation available. The
vapor phase process uses the standard kerosene cycle method.
In this system, kerosene is vaporized and drawn by vacuum
into a heated autoclave where the transformer has been
placed. Condensation of the vapor on the core and coil
assembly rapidly causes the temperature to rise and allows
moisture to be drawn out of the insulation by the vacuum. High
temperature and pressure are used to accelerate the drying
process.
When the power factor measurements and the removal rate of
moisture have reached the required levels, the flow of kerosene
vapor is stopped and a high vacuum is used to boil off the
remaining moisture and kerosene. Because so much water is
TANKING
After vacuum drying process the active part is removed from
the Oven and all components subject to the shrinkage are
tightened again. The core & coil assembly is then placed into
the tank and properly lacked up during the transformer
manufacturing process. The temperature and exposure time is
monitored during this time to ensure that the transformer is not
too cool by the time it is get off from the oven. While in higher
rating transformer, the vacuum is drawn for a period of time
dependent on the voltage of the unit and time for which the
active part was exposed to the atmosphere and the humidity at
the time. The vacuum period is between 12 to 35 hours.
Meanwhile the external wiring and termination work to be
completed as per customer requirements.
PAINTING
TECHNICAL DEVELOPMENT
Loading capability of power transformers is limited mainly by
winding temperature. As part of acceptance tests on new units,
the temperature rise test is intended to demonstrate that at full
load and rated ambient temperature, the average winding
temperature will not exceed the limits set by industry
standards. However the temperature of the winding is not
uniform and the real limiting factor is actually the hottest
section of the winding commonly called winding hot spot. This
hot spot area is located somewhere toward the top of the
transformer, and not accessible for direct measurement with
usual methods. The temperature of solid insulation is the main
factor of transformer aging. With temperature and time, the
cellulose insulation undergoes a depolymerization process. As
the cellulose chain gets shorter the mechanical properties of
paper such as tensile strength and elasticity degrades.
Eventually the paper become brittle and is not capable
of withstanding short circuit forces and even normal vibrations
that are part of
Transformer life. This situation characterizes the end of life of
the solid insulation. Since it is not reversible, it also defines the
transformer end of life
This process is well known to transformer owners and sustained
efforts have been made to monitor the hot spot temperature to
take advantage of cool ambient
Temperature, extend the transformer life while providing
emergency overloading capabilities and taking advantage of
market opportunities. Figure 1 shows the sensitivity of paper to
temperature. Modern transformers make use of thermally
upgraded paper that has been chemically treated to improve
the stability of cellulose structure. The rated hot spot
temperature for this kind of paper is 110C and it can be seen
that an increase 7C will double the aging acceleration factor.
For older transformer build with normal Kraft paper, the rated
hot spot temperature is either 95C according to IEEE or
97Caccording to IEC. This paper is also very sensitive to
temperature and in case of emergency (assuming a hot spot
temperature of 140C) the aging acceleration factor is about
100, which means one hour in this condition is equivalent to
100 hours at the rated temperature.
Wet transformers (solid insulation showing more than 2% water
content) incur an
BUSHINGS
BUSHING FAILURE
Bushings sometimes fail due to partial discharge degradation in
the insulation. There is at present great interest in the
electricity supply industry in monitoring the condition of high
voltage bushings.
TESTING
Impulse Testing
A state-of-the-art digital impulse recording system, the Haefely
HIAS system, provides the most accurate analysis of impulse
results available today. Electronic recording of the impulse
current and voltage waveforms allows quick mathematical
comparisons to be made, including the difference between the
two waveforms under scrutiny. Accurate printed and plotted
final results are quickly available. If required, photographic
transparencies from the impulse oscilloscope can be supplied.
The construction of the test area incorporates a complete
copper mesh ground mat system, with extensive grounding
points provided. This eliminates high impedance grounds and
provides exceptionally clean test records. The impulse
generator is rated at 200 kV per stage for a total of 2.8 MV,
with 210 kJ total stored energy. For precise triggering, this
generator is equipped with a pressurized polytrigatron gap in
each stage. For chopped wave tests, a Haefely multiple
chopping gap is used. Our plants are fully capable of
performing lightning impulse, switching impulse and front-ofwave tests as required.
Induced Testing
For induced testing, a variable voltage alternator, rated
1500/1000 kVA, 3/1-phase, 170/240 Hz, is used. Voltage control
is by solid state automatic voltage regulator, and solid state
speed control of the 1000 kW DC driving motor. During the
induced test, partial discharge measurements both in pC and
V are taken and equipment is available to locate internal
partial discharges by the triangulation method.
Loss Measurement
Power is provided to the loss measuring system by a 5/10 MVA
regulating transformer feeding three single-phase 10 MVA
variable ratio transformers and a 110 MVAR capacitor bank.
Losses are measured by an automated system using CTs for
current and gas capacitors for voltage. This system has a fully
automated digital readout and printer.
AC Testing
A test supply with an output voltage infinitely adjustable from
3-350 kV is available for high voltage AC testing. To measure
the applied voltage level, a digital peak-responding RMS
calibrated voltmeter capable of measuring up to 1600 kV is
used.
Short-circuit testing