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T.K. Ganguli
M.V. Prabhakar
a. Core building
b. Preparation of windings
e. Processing
The core forms the magnetic circuit of the transformer. Core is built up from cold
rolled grain oriented, silicon alloy sheet steel of the best magnetic properties. The
material is either received in rolled coil form or in finished sizes of core sheets,
ready for core building. When the material is received in coil form, it is slitted,
cropped and mitred to the required dimensions based on the design
requirements. CNC machines are now available which can perform the above
operations with perfect control on burrs. The size, type, and construction of the
core, like the number of steps, number of limbs, height, etc. depend on the
number of phases and the size of the transformer.
The sequence of operations for core building and assembly are as under:
h. Core building.
j. Tightening of core.
k. Lifting of core by use of a cradle, and carrying out isolation checks after
treatment of insulation items.
The core assembly is now ready for further processing and assembly.
c. Dressing of the mould, i.e. assembly of insulation spacers and blocks on the
mould.
h. After removing the winding from the winding machine, each winding is
clamped between top and bottom plates through tie rods, and kept in an oven
for heating. The windings are individually shrunk to the required axial
dimensions by heating in the steam heated oven and by applying the required
pressure. Heating ensures removal of moisture from the insulation items. This
process is called stabilization of the windings, and the windings are stabilized
to such an extent that they do not shrink further during service.
Layer winding is also clamped and shrunk as above. Winding is then placed with
bottom end in top position and the bottom end insulation consisting of angle
rings, angle washers, flanged paper insulation, block washers, etc., is built up.
The position of winding is then reversed, bringing top of winding on top and the
top insulation arrangement is completed in this position. During this process,
insertion of line shield rings on both ends and filler paper, preparation of leads,
placement of circular barriers, etc., are also completed. After completion of
insulation arrangement, the coil is shrunk to the required axial dimensions.
The winding is then kept in clamped condition for either composite winding
assembly or assembly on core legs.
b. Insulation items, i.e. block washers, angle rings, etc., are assembled. During
insulation assembly, various leads i.e. tapping, line leads, etc., are properly
positioned and partly insulated at this stage.
c. Winding assembly is reversed to bring top of the coil at the top. Insulation
items of top portion are then assembled, and various leads are also prepared.
The individual windings alternatively can also be assembled on the core leg
instead of being pre-assembled.
12.4. Core and Winding Assembly
Core is placed on suitable levelled platform. Top-end frame and yoke laminations
are removed. Bottom insulation items are placed on bottom yoke/end frame on
each core leg. Various windings are either lowered one by one or composite
winding assembly is lowered on each core leg. After lowering of the windings, top
insulation arrangement is completed. Top-end frame and yoke laminations are
placed back in position. Coils are kept under pressure by either coil clamping
bolts or spring loaded hydraulic devices provided on the top-end frame. A typical
arrangement of core and winding assembly is shown in Fig. 12.3 (Plate 5).
Figure 12.3.
After relacing of the top yoke, the preparation of the Terminal Gear Assembly is
done as described below:
Figure 12.4(a).
Figure 12.4(b).
Figures 12.5(a) and (b) (Plate 6) shows photographs of typical HV terminal gear
arrangements.
Figure 12.5(a).
Figure 12.5(b).
After completion of terminal gear assembly, the core and winding assembly is
placed in the tank. The tank may either be of conventional or bell-shaped
construction depending upon requirement. In case of bell-shaped construction,
the top part of tank and for conventional construction the bottom tank is
prepared for this purpose. Preparations include mounting of shunts, barriers, etc.,
on tank walls as required and also laying of gaskets on the flange joints. In
conventional tank, the core and winding assembly is lowered in the bottom tank.
[Fig. 12.6(a) (Plate 6)]
Figure 12.6(a).
In bell-shaped tank construction, top tank is lowered on the core and winding
assembly. [Fig. 12.6(b) (Plate 6)]
Figure 12.6(b).
After placement of core and winding assembly in tank, various electrical and
mechanical clearances, viz. coils to tank, line, neutral and tapping leads to tank,
etc., are checked. After the above checks are over, all the openings in tank and
cover are blanked by blanking plates and gaskets. The transformer is then sent
for drying and impregnation.
12.7. Processing
The quality of a transformer and, consequently its performance and life depends
essentially on the factory processing. The assembled active part of the
transformer after tanking or before tanking as the case may be, is heated in an
oven for extraction of moisture under vacuum. Sometimes, vacuum drying is
done by drawing vacuum in its own tank and keeping the whole transformer in an
oven.
Besides the conventional method of drying, the most modern vapour phase
drying method is also used, as explained in detail in Chapter 13.
Much importance is attached to proper dry out, as otherwise windings would
become loose in service, and may get distorted under short circuit conditions.
Once the moisture is extracted to the desired level, oil is filled under vacuum and
the transformer is soaked in oil.
The transformer active part is then taken out and all the terminal gear cleating of
the leads are retightened and the coils are clamped and secured in position. The
transformer tank cover is then placed in its position and the transformer is now
ready for further assembly of bushings etc.
12.9. Tanking
After servicing the transformer is assembled with all the necessary fittings. The
oil is filled under vacuum and it is circulated in order to get the desired ppm and
BDV levels before being offered for final testing and subjected to high voltage
testing.
Citation
EXPORT
BHEL (Bharat Heavy Electricals Limited): Transformers, Second Edition.
Manufacturing and Assembly, Chapter (McGraw-Hill Professional, 2003),
AccessEngineering
This product incorporates part of the open source Protégé system. Protégé is
available at http://protege.stanford.edu//