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CHAPTER 1
INTRODUCTION
As per the revised syllabus for B.Tech from Mahatma Gandhi University
every student is supposed to attend a 10 days internship program from any 2 reputed
industries. Our group comprising of 6 members got permission from TELK to
participate in their 3 day internship program. The program was from 13-06-2013 to
15-06-2013. We also got permission from KEL to participate in their 7 days internship
program. KEL internship program was from 17-06-2013 to 24-06-2013.
CHAPTER 2
KEL
The transformer division with an annual production capacity of 6,00,000 kVA soon
after its inception, emerged as a major player in designing and manufacturing
Distribution Transformers of ratings upto 5,000 kVA, 33 kV Class. Manufacturing
custom-built transformers, for specific requirements, is yet another specialty of KEL.
The KEL transformer factory is one of the first few transformer factories in India, to
get ISO 9001 Certification. KEL transformers, approved by the national test house,
various state electricity boards and power corporations in the country, are type tested
at Central Power Research Institute, Bangalore.
CHAPTER 3
DISTRIBUTION TRANSFORMER
The three-phase transformers with a pad installed on them are used with an
underground primary circuit, whereas three single-phase pole type transformers are
used for overhead services
There are some distribution transformers, which can also offer network services. They
are usually mounted in an underground vault. In this type of transformers, power is
supplied through underground cables. Advantages of distribution transformer is that
they have excellent capacity to withstand overloads
CHAPTER 4
PARTS OF A TRANSFORMER
4.1. CORE:
4.2. WINDING:
4.3. OIL:
Transformer oil is mineral oil and is hydro-carbon compound. This oil is getting from
refineries. Transformer oil is used as insulation medium and cooling. Low viscosity
oil provides better cooling.
4.4. TANK:
4.5. BUSHINGS:
It is a safety device mainly used in transformer to protect tank from bursting due to
excessive pressure developed inside in fault condition.
4.7. CONSERVATOR:
It conserves the oil inside the transformer. Usually it is in cylindrical shape. In high
voltage transformer inside conservator there is a rubber bellow/air cell to prevent the
ingress of moisture present in the air during breathing from outside. These rubber
bellow/air cells prevent the direct contact of air to the transformer oil inside the
transformer.
In many cases separately mounted cooler banks are used. It consists of cooler
connecting pipes, radiators, fans, pumps etc.
OLTC is used along with transformer for getting desired output voltage. The tap leads
of the tap winding are being connected to the OLTC Tap selector. The oil inside
OLTC will not allow mixing with the main oil. Since this oil will be contaminated
during the operation of OLTC. There is a separate conservator for OLTC in addition
to main conservator. OLTC is usually connected to the HV side.
These are used for measuring temperature of oil and for the temperature of winding.
4.12. BREATHER:
This is used for breathing and for preventing the entry of moisture in the transformer
oil when the transformer breaths. The dust in the air sucking from the atmospheres
passes through an oil cup provided in the bottom of the breather. The dust in the air
will be collected in the oil cup. Silica-gel will absorb moisture content present in the
breathing air.
Usually two control panels are provided with power transformer for controlling
OLTC operation and cooling control action.
Thermosyphon filters are intended for prolonging Transformer oil life by abstracting
harmful constituents like water content from it.
These oil level indicators are used to indicate oil inside the transformer tank.
Types of cooling
Depending upon the rating of transformer different types of cooling are adapted.
Usually types of cooling adapted for a transformer at different load are being
indicated in the transformer name plate. Transformer cooling arrangement can be
done in various ways.
2.The surface areas of the radiators have enough area to dissipate heat to
theatmosphere while hot oil is passing through the radiators. Radiators are arranged in
two fashions. One is mounting to the tank directly (Tank mounted Radiators) and
Radiators can also arrange to form a bank. This is required for Transformer for higher
rating for more heat dissipations.
OFAF and OFWF type of cooling methods require oil circulating pumps in the
cooling circuit of Transformer.
CHAPTER 5
SECTIONS AT KEL
In an electrical power transformer there are primary, secondary and may be tertiary
windings. The performance of a transformer mainly depends upon the flux linkages
between these windings. For efficient flux linking between these winding one low
reluctance magnetic path common to all windings, should be provided in the
transformer. This low reluctance magnetic path in transformer is known as core of
transformer.
Cores are made of grain oriented, low loss magnetic cold-rolled silicon steel. Both
sides of steel sheets are laminated with ceramic insulation. This is the section where
transformer core is being fabricated and assembled. Main core material (CRGO) is
getting in rolled condition and this material is being imported. At present there are no
Indian manufacturers producing CRGO. This core is also getting in fabricated
condition from different Indian companies like Mahindra, Nexus, Crips etc. (All
materials are importing). Thickness of CRGO sheet is 0.24~0.30 mm.
be insulated more to withstand the higher voltage across it. HV also needs more
clearance to the core, yoke or the body. These aspects influence the type of the
winding used for the HV or LV windings. Transformer coils can be broadly classified
in to concentric coils and sandwiched coils. The former are very common with core
type transformers while the latter one are common with shell type transformers.
Conductor insulation:
KEL Mamala is associated with construction of transformers with disc type coils. The
HV and LV windings are done using vertical winding machine and horizontal
winding machine. Disc coils consist of at conductors wound in a spiral form at the
same place spiralling outwards. Alternate discs are made to spiral from outside
towards the centre. Sectional discs or continuous discs may be used. These have
excellent thermal properties and the behaviour of the winding is highly predictable.
Winding of a continuous disc winding needs specialized skills. The insulation used in
the case of electrical conductors in a transformer is varnish or enamel in dry type of
transformers. In transformers, to improve the heat transfer characteristics the
conductors are insulated using un-impregnated paper and the whole core-winding
assembly is immersed in a tank containing transformer oil. Around the HV winding, a
layer of Kraft paper is wound. Normally the Kraft paper acts as a paper, but when its
mechanical property comes in contact with the transformer oil changes and behaves
like an insulating material. In the winding section, all insulation work, coil winding,
coil assembly are assembled.
Here assembly of core, coil and tanks are being done. Core and core clamp assembly
will get from the core working shop and assembled coil per phase (HV, MV and LV
separately wound and then assembled together) from the C & I (Coil & Insulation)
shop. After dismantling upper yoke the assembled coil will insert over the three limbs
of core using EOT crane. After completion of coil insertion upper yoke will be rebuilt.
Next stage is internal assembly work. i.e. Tap-lead formation, bushing lead formation,
providing proper insulation at right place for getting insulation strength etc. All these
work are being done as drying to remove the moisture present in the insulation
material. Presence of moisture will reduce the insulation level (quality) of the
transformer. After drying, the next process is re-clamping (re-tightening of parts
which are shrinkage due to drying). After re-clamping the dried transformer and re-
clamped internal body.(Core and Coil) put in its tank. Components and accessories
like Transformer Bushing, conservator, relay line, protective devices such as Bucholz
relay, PRD/ Bursting head assembly, Pipe assembly, and Cooler bank assembly
including radiators which are being completed.
After completion of assembling, the work is inserted in the tank, hot, degassed oil is
then allowed into the transformer tank.
Oil is then circulated through the transformer until all gas trapped in the core,
windings, and the insulation is removed.
The Transformer Turns Ratio test is used to make sure that the Turns Ratio between
the windings of the transformer is correct. With this information, you can decide what
the output voltage of the transformer will be. The ratio is calculated under no-load
conditions.
Winding resistance measured is required for computing load losses, regulation and
efficiency of transformer.
The pupose of this test is to determine no loaad loss or coreloss and no load current
which is helpful in finding Xo and Ro.The wattmeter ,ammeter and voltmeter are
connected to the LV side.The HV winding is kept open and LV winding is connected
to supply of normal voltage and frequency.By autotransformer the apllied voltage is
made equal to voltage rating of LV side. Therefore it is seen that the open circuit test
on transformer is used to determine core losses in transformer and parameters of shunt
branch of the equivalent circuit of transformer.
The LV side of the transformer is short circuited . The applied voltage is slowly
increase until the ammeter gives reading equal to the rated current of the HV side.
After reaching at rated current of HV side, all three instruments reading (Voltmeter,
Ammeter and Watt-meter readings) are recorded.
The Short Circuit test on transformer is used to determine copper loss in transformer.
CHAPTER 6
TELK
TELK is renowned for the quality of its products, earned through the last 3
decades of impeccable supply and services all over India and outside India. The
company supplies its equipment’s to all over India as well as Oman. Malaysia,
Indonesia, Nigeria, etc.
600 MVA (3 x Single Phase Bank) for India’s first 500MW Thermal Power
Station at Trombay for TATA
CHAPTER 7
WORKSHOPS AT TELK
PT manufactured is suitable for connection between the line and effectively earthed
systems. The standard secondary voltage is 110V and 110/√3V. The grounding type
PT consist of primary and secondary/tertiary winding, core, lower tank and expansion
chamber/ The core is made of CRGO steel and has three limbed construction. The
secondary/tertiary and primary terminals are wound concentrically around the core.
The assembly is placed in a tank. The secondary/tertiary terminals are brought out and
terminated in a terminal box fitted to the side of the tank. The terminals of the primary
winding is brought out through a small bushing and connected to the tank.
7.1.3 BUSHINGS
The Oil impregnated paper insulated bushings are used to connect overhead lines to
transformer. This is mounted on transformer in vertical or horizontal position at a
maximum inclination of 30º from vertical. The active part of bushing consists of a
condenser body build up around a centre tube using high quality Kraft papers. A disk
spring assembly is located in the top housing holds all synthetic rubber gaskets and O-
rings between porcelain and metal parts under controlled pressure, completely sealing
the bushing.. An oil sight window is provided in the expansion chamber for observing
the oil lever. The space in the expansion chamber above oil is filled with dry nitrogen
gas. Due to the hermetic sealing the bushings are maintenance free and non-
susceptible to aging. Oil Impregnated Paper (OIP) type high voltage condenser
bushings were manufactured by TELK in 1970.
This section deals with the procedure of fabrication CRGO, lamination, assembly of
transformer core and manufacture of ring core for current transformer, tank sheet and
lamination for PT. the various activities in the core section are listed below.
7.2.1 SLITTING
This is the process of cutting the CRGO coil into different widths. This process is
done in gang slitting line. After slitting operation separate tags will be affixed inside
and outside of the coil containing all the details for identification.
7.2.2 MITRING
The is the process of cutting slit widths into required design shape such as the
trapezium, parallelogram, rectangle, etc., are specifies in the core cutting drawing.
The selection of Mitre Shear Line (MSL) is done according to the angle specification
detailed in the core cutting drawing. There are five numbers of MSL in core shop.
Nibbling of corner as per core cutting drawing is called shearing. Square shear are
used for this purpose.
7.2.4 DE-BURRING
A process to remove burrs on mitred portion is called de-burring. Check the burr after
every 200 lamination with a tolerance level less than 0.02 mm.
7.2.5 ANNEALING
Stresses are introduced into silicon steels whenever they are slitted or sheared into
laminations. These stresses have an adverse effect on magnetic properties, such as
core loss and permeability in order to relieve the stress and restore the original
magnetic properties annealing is necessary. It also reduces the effect of sharp work
edges and improves flatness.
7.2.6 SORTING
The finished laminations for transformer assembly are arranged in wooden planks in
order to the sequence of steps as per sheet arrangement drawing. This process is
called sorting. The fabrication stage of core is completed when the sorting job is over.
Generally, rectangular Paper Covered Copper Conductors (PCC) is used for winding.
For vary high power transformers continuously transposed conductors (CTC) are
used. CTC is made of a bunch of rectangular enameled copper conductors which are
transposed and then covered with electrical grade Kraft paper. This reduces the
copper loss and size of winding. The copper conductors are made from Electrolytic
Tough Pitched (ETP) copper and are of high annealed copper.
Helical winding
Used for relatively low voltage and high current rating transformers
Coils are wound like a helical spring with several conductors arranged in single or
multiple groups and connected in parallel.
The conductors are transposed at intervals.
Cylindrical winding
Continuous winding
Radial spacers locked to the axial spacers separate disc coil sections and establish
oil directs branching from the main axial ducts inside the winding.
Kraft Paper
The Kraft paper is made entirely from wood pulp. The tensile strength of paper shall
not be less than 55MN/m2 in the longitudinal direction and 20MN/m2 in the transverse
direction.
Press Board
Used in insulating transformer windings. Press board is used for making winding
cylinders, axial and radial spacers, oil ducts, oil guide rings, etc. The breakdown
voltage of the press board is greater than 20kV/mm (in oil)
Tetron Cord
It is used in power transformer to tie together various leads and insulating structures.
The cord has high shrinkage property to avoid loose knot. The minimum shrinkage
must be 5%.
Oil filling is done under vacuum. Before filling the quality of the oil has to be
checked. In order to remove foreign materials trapped in the coil during
manufacturing and processing stages like cotton treads, dust, etc flushing of oil is
done. The temperature is maintained at 60º to 80º.
Tap change operation requires two rotatory switches per phase. The odd numbered
tapping ate connected to one switch and even numbered tapings are connected to the
other in such a way that the two switches come into use alternatively. The odd and
even tappings are selected by the diverting switch using roller type intermittent gear
mechanism instead of usual Geneva gear mechanism for reducing friction.
Simultaneously with operation of tap selector, the spring mechanism which is the
energy accumulated mounted on the top of the diverter switch will be changed.
laboratory for tests conducted as per Indian standards/ IEC/ or British Standards/
ANSI / NEMA.
BCT continuity check is done using a continuity tester. OLTC continuity check is
done using voltmeter in one winding keeping the other winding placed as a
convenient level.
Winding resistance measured is required for computing load losses, regulation and
efficiency of transformer.
Voltage ration error measurement is done using a transformer turns ration meter. A
low voltage is applied to the low voltage side of the transformer under test and the
standard transformer and the voltage induced on the low voltage side is compared
with a galvanometer. The fine tapping of the standard transformer is adjusted until the
galvanometer indicates minimum deflection. The % ratio error (% ratio error =
(Design ratio – Measured ratio x 100)/Design ratio) can be read directly on the
instrument dials.
CHAPTER 8
CONCLUSION
The training provided by KEL and TELK provides a comprehensive coverage of
various products manufactured such as distribution transformers, power transformers,
current transformers and potential transformers of different types. It’s operation,
product information about the nature, characteristic of material and also imparted
knowledge of various technologies used by the company. The industrial exposure
gave a sense of knowledge about the day to day activities and workings of a fully
fledged electromechanical component of manufacturing company.