TECHNICAL PRESENTATION ON TRANSFORMERS 1. What is a transformer?. Transformer is a static electric device that transfers energy by inductive coupling. 2.

Types of transformers a. Distribution Transformer: 1. Distribution transformers are the last transformers in a Power system. They transfer energy from distributors primary circuit to consumers service circuit. 2. Loading is variable. 3. Small MVA ratings i.e 16 KVA to 4.0 MVA. 4. Relatively lower voltage ratings i.e 3.3 KV to 33 KV on secondary side & 0.433 KV (3 phase) & 0.24 KV (1 phase) on secondary side. 5. Vector group is D-yn6. Lower specific weight as compared to Power transformers. b. Power Transformers. 1. Transformers that are used in transmission networks are Power Transformers. That is they distribute power from generating station to distributors primary circuit. 2. Loading of Power transformers is fixed and is near to 100 %. 3. MVA ratings are typically 5 MVA & above. 4. Typical voltage ratings are 33 KV and above. 5. The specific weight is higher than distribution transformers & they operate near the knee point of the B-H curve just below saturation point. c. Power export duty transformer. 1. Also called Generator transformers.(GSU-generator step up transformer) 2. LV winding is connected to generator & HV winding to transmission network. 3. Desirable characteristics of a generator transformer are Low loss , low noise, Low partial discharge, good SC withstand ability & reliability.

4. Vector group is generally Ynd- 1 or Ynd-11. d. Converter-duty transformers 1. Designed to handle load having non-linear content like VFDs. 2. 3 winding transformers used for 12 pulse loads & 2 winding for 6 pulse loads. 3. Phase shift in secondary windings in case of 3 winding transformer. 4. Zig-Zag windings used in secondary at times to reduce harmonics. e. Earthing transformers. 1. Provides neutral path for grounding purpose. Thus its main purpose is to pass ground current during earth fault. 2. Permit the circulation of unbalanced load current in the neutral. 3. Limit the current during earth fault. 4. At time provide single phase to neutral load.

3. Important parameters to specify the transformers : a. KVA Rating 1. Indicates the amount of power the machine can deliver when fully charged. 2. MVA rating is different than Power delivered by transformer. MVA rating supplies both active & reactive power. We use only active Power. 3. MVA rating is dependent on the type of cooling used. It increases by a factor of 20 % between ONAN & ONAF. 4. MVA rating depends on the permissible temperature rise of windings. b. Voltage class. 1. Decides the Basic Insulation level of the transformer. 2. Highest system voltage versus KV rating of transformer. 3. IEEE classifies 66 KV & below as class-I transformers. 110 KV & above are class- II transformers. Additional tests like DGA/Lightning impulse/PD for bushings-windings are done for Class-II transformers.

c. Vector group ( importance of zig-zag / where Ynd1 & where Ynd11). 1. Signifies 3 things , voltage class of Pri-secondary windings ,Location of the neutral point & phase shift between primary & secondary.. 2. Different applications have different vector groups. i. Distribution : Dyn11 or Dyn1

ii. GSU transformer : Ynd1 or Ynd11 iii. Earthing transformer : Zn0. iv. Converter duty : Dd0yn11 or Dz11. 3. Importance of vector group is very high if the transformers are used in parallel operation as the 2 transformers should have same vector group. 4. Zig-Zag vector group : i. ii. iii. iv. Also known as inter-connected star winding. Used in earthing transformers & transformers for converter duty applications. Reduces 3rd harmonic voltage & allows unbalanced loading. Preferred where Delta is weak due to large number of turns & small cross section.

d. Losses (CAPEX Vs. OPEX). i. ii. iii. iv. 3 major components , iron loss also known as no-load loss , copper loss also known as load loss & auxiliary loss. Iron loss is the energy spent in establishing a magnetic field in the magnetic circuit of the transformer. Copper loss or load loss is primarily I-2 loss. But it also has stray loss component. Stray losses :

A. Due to magnetic leakage flux in various parts of transformer like tank, clamps etc. B. Winding stray losses due to eddy currents (skin effect) circulating currents in parallel strands.

C. Higher the SC impedance higher the stray losses. D. Stray losses can cause local over-heating (hot-spots) in large Power transformers. v. Lower the losses higher the cost of transformer ( higher CAPEX) but lower the ownership cost of the equipment (lower OPEX).

e. Impedance ( How it affects regulation/fault levels), positive sequence impedance/zero sequence impedance- significance. 1. Voltage drop due to winding resistance & leakage reactance expressed in percentage of full load voltage is impedance. 2. Voltage drop which occurs under full load (current) is called regulation. 3. Impedance has major effect on system fault level. Higher the impedance lower the system fault level & vice-versa. 4. Zero sequence impedance : i. ii. iii. When load is balanced then Z-1 = Z & Z0 = 0. When load is unbalanced then zero-sequence current flows through the neutral. The magnitude of zero sequence current depends upon zero sequence impedance & balancing Ampere-turns in the transformer.

f. Magnetizing current ( difference between no load current & in-rush current) 1. Current flowing thru primary winding of the transformer when secondary winding is open circuited is no-load current of transformer. 2. The major part of no load current is magnetizing current of transformer. The other smaller part being eddy current. 3. The no load current is typical range of 0.5 % (Power transformers) to 2.5 % (small distribution transformers) of full load current. 4. No load current is different from in-rush current. 5. In rush current is a form of over-current during energizing of a transformer. It is 4-8 times the Full load current. 6. It lasts for few tens of cycles. 4. Sizing of transformers

a. Over-sized &Under-sized transformers dis-advantages. 1. The size (MVA) of a transformer = 1.732 X V(Ph) X I (line). 2. I( Line) is called load of a transformer. 3. The size of transformer is dependent on Installed Load, Demand factor & diversity factor. 4. Over-sized transformer has higher no-load losses & higher installation cost. They also mean higher system fault levels. 5. Under-sized transformer gets frequently over-loaded. 6. Certain level of over-loading is allowed. The duration for which transformer can be over-loaded depends on ambient temperature & percent overload. 7. Overloading beyond permissible limits causes irrevocable damage to the transformer insulation. b. Sizing of transformers for motor-start application. 1. While starting the motors draw a heavy in-rush current at a low Power factor. 2. This is like a soft short circuit , where the conditions are similar that is current is drained to earth at a low power factor. 3. In-rush is accompanied with a dip in voltage. 4. It is advisable to use RVS or soft-starters for HP motor applications. 5. For transformers dedicated to motor application transformers with higher impedance are advised. c. Sizing of transformers for Power export application. 1. Generators have a service factor of 10 % . They supply load at a Power factor of 0.8 -0.9 hence the generator transformers must be rated at about 25 % over the generator capacity. 2. Generators operate at maximum efficiency when loaded at 60-75 %. Hence maximum efficiency of transformer should match generator efficiency pattern. 3. Load throw-off. 1. ONAF sizing ONAF : oil natural air forced cooling.

2. Some transformers have ONAN/ONAF-1/ONAF-2 ratings. 3. The rating of transformer is constrained by hot-spot temperature. ONAF cooling reduces top-oil temperature & hence hot-spot temperature & increases the rating of transformer. 4. Generally MVA (ONAF) = 1.2-1.25 X MVA (ONAN). 5. Any further cooling shall increase the current density. 5. Protection features/accessories on a transformer Transformer has various protective devices . i. Buchlozs relay : Gas operated device & can detect incipient fault.

1. BR is a gas & oil level operated device. It detects the following faults : A. Low oil level : Due to oil leakage , the oil level drops & bubbles are formed which are detected by BR. B. Formation of gas : because of Phase to earth faults , the transformer oil decomposes leading to formation of gases like CO-2 , CO. These gases accumulate in the top of BR causing alarm contact to operate. C. Development of stud pressure : Severe faults like Short-circuit between phase- Phase or Phase-earth or faults in tap-changing equipment causes surge in oil . The oil surge strikes the buffer plate causing mercury switch to close. 2. Nuisance operation of BR . Mechanical lock is provided in BR to prevent its nuisance operation. A. When oil is being topped up air bubbles enter in the transformer along with the oil causing BR to trip. B. Movement of the glass-bulb of the mercury switch during transportation. 3. Precautions while installing BR : A. Isolation valves on both sides of the BR must be open. B. Relay must be set inclined to horizontal plane @ 3deg to 9 deg. C. Arrow marked on the relay must point towards conservator. ii. OTI/WTI : winding temperature & oil temperature indicators.

A. These are capillary type dial thermometers.

B. The bulbs are immersed in oil filled thermo-meter pockets ion the coverplate of the transformer. C. The liquid in the bulb which is in contact with oil expands resulting in increase in pressure d pressure of the system. This increase in pressure results in movement of the bellow. A link lever mechanism amplifies the movement to the disk carrying pointer. D. In WTI the oil is heated with a image coil. This coil is a resistance which is fed by a representative current flowing through the transformer. E. WTI/OTI readings are also used for change over from ONAN to ONAF cooling. F. Temperature difference between WTI & OTI is 5-10 deg C. iii. Explosion vent/PRV.

a. Explosion Vent : A. Provided on the top plate of the transformer tank. B. It has two diaphragms, one at the tank end & other at the top end. C. During a fault large amount of gases are formed due to pressure of gases lower diaphragm ruptures first & then the upper diaphragm. D. Draw-back of Explosion vent : after the diaphragms are ruptured on operation of Explosion vent. The oil in the transformer is exposed to the atmosphere & the transformer is not isolated from the system. These drawbacks are removed by PRV. E. Precaution : Since diaphragms are not designed for P & V test they must be removed before carrying out the test. b. PRV: Pressure release valve. A. Basic purpose of PRV is to prevent mechanical damage to transformer by releasing any excess pressure over the set limit. B. It is a spring loaded device which automatically closes when the pressure drops to the set limit after the excess pressure is vented. The transformer is isolated by tripping of the circuit breaker. C. Visual indication of PRV is provided by the operating flag. D. PRV is designed for specific operational pressure which cannot be changed at site. Hence it is advisable not to disturb the clamping arrangement of the spring.

iv.

MOG. A. It is a direct indicating device mounted on the conservator of the transformer. B. It operates when the oil level falls to a low level. C. It has a disk indicator and a float. The two are linked to each other magnetically. That is there is a driver-magnet & a follower magnet. D. Precaution : The float & the arm are detached from the bevel-gear mechanism during transportation to avoid transit damage. They are also locked in position.

v.

Silica gel breather. A. The transformer oil expands & contracts due to change I ambient temperature & load. B. The air in the transformer is either forced out (when the oil expands) or sucked in (when the oil contracts). C. When the air is sucked in the dust & the moisture present in the air also comes in. silica gel breather are used to prevent this so that only dry & clean air is breathed in & out of the transformer. D. It has a transparent casing, silica crystals & a oil seal. E. Operation : 1. Dry silica crystals which are deep blue in color have good capacity to absorb moisture. Silica gel turns its color from deep blue to pink on absorption of moisture. 2. Pink crystals have to be reactivated so that they may be used again. 3. The oil seal acts as a barrier between outside air & silica gel crystals when there is no flow of air.

6. Our QA (special features) The quality of transformer is largely dependent quality of the raw material used & the work-man ship during manufacture. The salient features being: a. QA for raw material . (tests on lamination/tank/windings/bought out components)

A. Tank : i. ii. iii. iv. v. Tanks are fabricated from good-quality low carbon steel. Stiffeners are provided to strengthen tank plates. Adequate space is provided in the bottom of the tank for collection of sediments. All seams and joints are double welded (where-ever possible) In case of high capacity, high impedance transformers increased clearances are taken & aluminum shields are used to minimize eddy current losses. Tanks are subjected to Pressure test that is oil head + 35 KN/sq.M & vacuum test.

vi.

B. Radiators : i. ii. We use tank mounted fin type radiators having a thickness of 1.2mm. Radiators are pressure tested at manufacturers end. They are pressure tested for 2 Kg/sq.cm in water for 30 minutes to ascertain leakages.

C. Laminations. i. ii. iii. iv. HI-B CRGO laminations are used. Core steel is coated with oxide-silicate coating. Laminations are checked for their dimensional confirmation that is thickness, width, mitered joints etc. Watt loss/ Kg is checked for laminations.

D. Transformer oil : i. ii. Mineral oil used for transformers confirming to IS or IEC standards. The characteristics like electric strength (BDV > 60 KV) , resistivity (@ 90 deg C > 10^12 Ohm-cm ), dielectric dissipation factor (tan < 0.05) is checked. If the above requirements are not met then the oil is processed till the requirements are met.

iii.

E. Copper :

i. ii. iii.

We have our own copper processing facility . We sell copper to other transformer manufacturers. We use 99.99 % pure ETP grade copper (cc-rods). The test conducted are as per IEC- ( dimensional check, insulation level, tensile strength, resistivity).

b. QA for the manufacturing process. i. The transformer manufacture involves following major mile-stones :

A. Winding B. Core-assembly C. Core-coil assembly D. Tanking E. Testing. ii. Several checks & tests are conducted at each of these steps. The details of these are mentioned in our QA-plan.

7. Testing of transformers : A. All transformers are subjected to routine tests. B. The routine tests are measurement of winding resistance, measurement of voltage ratio, checking vector group, measurement of leakage impedance, IR values, Measurement of losses, Dielectric tests (PF test, induced over-voltage test) , oil leakage tests , MBT. C. Type tests and special tests are: Temperature rise test, DGA test , Impulse voltage test, SC test, measurement of tan for HV & LV windings, acoustic noise level test, measurement of harmonic level in No-load current & Power taken by auxiliaries. D. Routine tests are compulsory whereas type tests & special tests are optional & are decided on case to case basis. E. Sequence of tests is test on transformer tank, temperature rise test, Pressure test on assembled transformer, impulse test, routine tests, & special tests. 8. Installation & commissioning.

a. As far as possible installation of transformer should be avoided in rainy season. b. Transformer should be installed on a strong foundation. Foundation should incorporate oil drain facility in case of fire or any other emergency. This is strongly recommended for large power transformers. c. When rollers are fitted tracks or rails must be used & rollers must be locked so as to avoid movement of transformer. d. Whenever blanking plates are removed for fixing detachable parts like bushings, radiators etc old gaskets must be removed & replaced by fresh gaskets. e. Further installation & maintenance manual. 9. Maintenance of transformers ;

a. Maintenance of the transformers is a continuous activity. b. Maintenance can be broken down to two parts one being inspection & the second being action taken if inspection shows un-satisfactory conditions. c. There are certain things about transformer which need to be inspected every few hours, other aspects needing inspection in every few months & still other may be once in 1 to 2 years. d. You may find a detailed note about this in our maintenance manual.