Categorizing the transformer production at GEMCO

Transformer

Distribution

Power

Core type

Shell type

Straight cut

Angular cut

ONAN(Oil natural Air natural)

Comparison between power & distribution transformer

Power Transformer

Distribution Transformer

Comparison between power & distribution transformer Power transformer Installation At substation (generation side). - or Y- , 3 wire. MVA. Usually stepped down to 11kv. ONAF, OFAF, ONWF, OFWF Distribution transformer At distribution and transmission (consumer side). -Y, 4wire. KVA. Usually stepped down from 11kv to 415v.

Connection Capacity Voltage rating

Cooling system

Usually ONAN.

Primary Distribution Transformers parts

Rod Gap Arrester

Transformer type
Core type transformer

Winding

Core

Comparison between core & shell type transformer

The advantages of each type are: core-type (or three limbs) is the most commonly used method of construction, the smaller core means less weight and expense. shell-type (or five limbs) is used for larger transformers because of a reduced height and better mechanical protection to the winding because it is surrounded by core. From a manufacturing standpoint, core-type & shell-type designs are very similar.

Transformer Core type

Comparison between core & shell type transformer

Angular Straight

Performance

Reduce reluctance against the Provides more reluctance magnetic flux by reducing the to magnetic flux due to gaps between sheets. Hence more number of gaps. So lessen the iron loss and performance is well below betters the performance. angular.

Cost

Cost is more as huge amount of core is wasted due to the cutting off at corner to make it angular. Preferred where efficiency is vital.

Cost is well below the angular cut.

Preference

Mostly used due to the less cost.

Products / Services:
I ) Transformers:

Power Transformer, 3 Phase, 33/11KV, 1 MVA to 5 MVA Distribution Transformer, 3 Phase, 33/0.415 KV, 100 KVA to 250 KVA Distribution Transformer, 3 Phase, 11/0.415 KV, 50 KVA to 500 KVA Distribution Transformer, 1 Phase, 6.35/0.24 KV, 5 KVA to 50 KVA Distribution Transformer, 1 Phase, 11/0.24 KV, 15 KVA to 25 KVA Apart from these, other rated transformer could manufactured as per requirements of clients up to 5MVA II)Repair & Miscellaneous Works: Damaged Distribution & Power Transformers up to 20 MVA

Process flow diagram

PPM

Design product Estimate cost Test raw materials Report

CPL

Plant

Electrical Mechanical

Test completed transformer Testing Report

Name of Raw Materials CRGO Silicon Steel Sheet Copper Strips Super Enameled Copper Wire Mild Steel Sheet HT Insulator Transformer Oil Insulated Paper & Board

Specification of materials Grade M-5 (width 0.3mm, density7.65kg/dm3, Core loss 0.97-1.39 for 1.5-1.7T)

Electrolytic Copper of 99.9% purity SWG -14 to 21 Copper of 99.9% purity Prime Quality Electrical Porcelain Insulator As per IEC-296 Class-1 Electrical Grade 100% Sulphate/Kraft Pulp

Design specification
Raw material specification LT Coil dimension, Thickness=5.6mm, width=11.2mm, insulation=.45mm, density=61.92x10^-6 kg/m3 HT coil type- SWG17 , supper enameled

dia-1.42-1.53, density= 8.9x10^-6 kg/m3

CRGO Silicon Electrical Steel Sheet with thickness 0.3mm &flux density Bm1.7Wb/m IEC Standard: 76 Vector group: DYN-11

Design specification
In design calculation The design is usually 6 step core section with Cylindrical coils

Summarizing the design: Specification of the transformer to be designed

Chose Ez, Bm,

Calculate Area and Diameter for core Find conductor size of HT & LT winding and calculate current density Choose layout of windings-- numbers of turns per layer , numbers of layers, distance between coils Calculate R, X, Z. Calculation of performance

Designing the tank

Transformer leg

Active Part

Tapping

Core

Insulation Board

Insulation Paper over winding

Each transformer undergoes following routine tests as per IEC 60076 requirements:
Di-electric strength test of transformer oil.

Testing

Measurement of Insulation Resistance.

High Voltage Test. Induced Over Voltage Test. Ratio Test. Vector Group Test. Measurement of No-Load Loss and Excitation Current. Measurement of Load-Loss and Impedance Voltage. Measurement of Winding Resistance.

Temperature Rise Test.