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A transformer is a device that transfers electrical energy from one circuit to another through
inductively coupled conductors²the 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:

By appropriate selection of the ratio of turns, a transformer thus allows an alternating current
(AC)voltage to be "stepped up" by making Ns greater than Np, or "stepped down" by
making Ns less than Np.

 

giving the ideal transformer equation


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Transformers for use at power or audio frequencies typically have cores made of
high permeability silicon steel. The steel has a permeability many times that of free space, and
the core thus serves to greatly reduce the magnetizing current, and confine the flux to a path
which closely couples the windings. The core is constructed by stacking layers of thin steel
laminations, a principle that has remained in use. Each lamination is insulated from its neighbors
by a thin non-conducting layer of insulation. The universal transformer equation indicates a
minimum cross-sectional area for the core to avoid saturation.
The effect of laminations is to confine eddy currents to highly elliptical paths that enclose little
flux, and so reduce their magnitude. Thinner laminations reduce losses, but are more laborious
and expensive to construct.
Laminating the core greatly reduces eddy-current losses
Distribution transformers can achieve low no-load losses by using cores made with low-loss
high-permeability silicon steel or amorphous (non-crystalline) metal alloy. The higher initial cost
of the core material is offset over the life of the transformer by its lower losses at light load.



Windings are usually arranged concentrically to minimize flux leakage. 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 enamelled magnet
wire, such as Form var 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.[64]

High-frequency transformers operating in the tens to hundreds of kilohertz often have windings
made of brazed 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. 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   .
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 power
distribution transformers the taps may be connected to an automatic on-load tap changer for
voltage regulation of distribution circuits.

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A major application of transformers is to increase voltage before transmitting electrical

energy over long distances through wires. Wires have resistance and so dissipate electrical
energy at a rate proportional to the square of the current through the wire. By
transforming electrical power to a high-voltage (and therefore low-current) form for transmission
and back again afterward, transformers enable economic transmission of power over long
distances. Consequently, transformers have shaped the electricity supply industry, permitting
generation to be located remotely from points of demand.
Transformers are also used extensively in electronic products to step down the supply voltage to
a level suitable for the low voltage circuits they contain. The transformer also electrically isolates
the end user from contact with the supply voltage.



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Expressing concerns over the delays in execution of the business plans of the NTPC-BHEL
Power projects Pvt Ltd (NBPPL), the power ministry has asked the joint venture partners to put
in extra efforts to implement the business plan so that the schedules of completion of Phase-I by
2012 and Phase-II by 2015 are achieved. The project currently running two years behind the
schedule, envisages capital investment of Rs. 1200 crore for establishing EPC capabilities and
manufacturing of BOP equipment like coal handling plant, ash handling plant in Phase-I to be
followed by capital investment of Rs. 4800 crore for establishing manufacturing facilities for
boiler, turbine and generator in Phase II with manufacturing capacity of 5000MW per year.
The current status of the implementation of the business plan has been reviewed and is noted that
the business plan was approved in October 2008 but the desired progress could not be achieved.
The secretaries directed the JV partners to identify major milestones and immediately sort out
any problem regarding implementation of the business plan and the schedule of operations.
NBPPL CMD C P Singh informed that a turnover of Rs.10,000 crore is expected by 2015 and
Rs.20,000 crore by 2020. Explaining the present order book position, he stated that currently
balance of plants (BoP) order worth Rs. 187 crore for gas based project of ONGC at Palatana,
Tripura and civil work and BoP worth Rs.199 crore for the gas based project from Namrup,
Assam have been received from BHEL and are under execution.

The DHI and the power ministry asked the joint venture company to take action to finalise the
partners for technical collaboration and identify the vendors for balance of plants (BoP) and
other activities over the next three months. The power secretary directed NBPPL to strive hard
to get more business with at least orders for Rs.3,000 crore over the coming two months.
Besides, the ministry asked BHEL and NTPC to expedite the requisite undertakings to NBPPL
for qualifying the company for participating in tenders and obtaining direct orders.

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BHEL Bhopal is a Leading Engineering Enterprise which Supplies wide Spectrum of Power
Transmission Systems/ Solutions from a single entity. It is a Leading Transformer Manufacturer
Offering wide range of Transformers. The product profile of BHEL Bhopal includes the
following:

—V Power Transformer
420KV CLASS, 50/60 Hz
1000 MVA, 3-phase
600 MVA,1-phase

765KV CLASS, 50/60 Hz

1000 MVA, 1-phase

1200KV CLASS, 50/60 Hz

1000 MVA ,1-phase

—V Shunt Reactor & Associated Ngrs

—V Controlled Shunt Reactor
420 KV CLASS, 50/60 Hz
200 MVA, 3-phase
150 MVA, 1-phase

765 KV CLASS, 50/60 Hz

110 MVA ,1-phase

—V HVDC Transformer & Smoothing Reactor

± 500kV / ± 800kV HVDC
CONVERTER
TRANSFORMERS
600 MVA, 3 WINDING,
1 PHASE

± 500kV HVDC SMOOTHING

REACTORS (OIL FILLED)
254 MVAr, 360 mH, 1568 Amp.

—V Instrument Transformers: CT, CVT, CVD

—V Transformer Bushings
 —V Tap Changers (On-load & Off-load)
—V Radiators and Unit OFAF Coolers

The Installed manufacturing capacity of BHEL Bhopal is 14000 mva/Annum

Annual Sales Turnover Range is US$ 70-75 Million
It has mainly two Manufacturing Units.
Having nearly 3 decades or over 30,000 man-years of experience, the facilities updated with
investments of over US$ 20 Millions. Dedicated shop area of over 80000 sq. meters and unique
Ultra High Voltage testing facility.
    

The LV voltage has low voltage at its terminals so the number of turns will also be less.
Normally, helical winding is used for LV side. The voltage on LV side is less so the current is
high as the power output is to be maintained constant. And to carry this much of high current, the
area of cross section of the conductors should be high. This is accomplished by adopting more
no. of conductors per turn.
Helical winding is a spring type winding and it suits most of the LV winding of transformers.

    

It has very high voltage at its terminals so the number of turns is also very large and it carries
very less amount of current. So, disc type winding is used where in a single disc can have 25
number of turns.

 !
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—V P.I.C.C.
—V C.T.C.
—V Bunched P.I.C.C.
—V Glued C.T.C.

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* After designing the windings they are suitably placed over the core legs keeping
in mind the electrical stresses.
* Windings are designed for impulse withstand and short circuit forces also.
* This is followed by the cooling design.

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* Any transformer consists of core and winding. Core is the magnetic circuit through which flux
flows.

p  
* The material used for core making is low reluctance magnetic steel containing silicon.This is
called ³CRGO´ i.e cold rolled grain oriented steel.
* The grain orientation is technology which ensures that the flux flow through the laminations
with minimum resistance,resulting in low core loss.

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There are following types of core available:-

I.V Three limb core

II.V Two limb core
III.V Five limb core
IV.V Core with elliptical yoke section
V.V Core with flat yoke

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Transformer tank is an enclosure which contains inside it the live parts such as core and winding
assembly, electrical connections and insulating oil.

 


—V Conventional Tank:
A tank in which the cover is flat and tank to cover junction is at the top of the tank.

—V Bell Type Tank

A tank in which the cover is not flat in shape and the tank and cover junction is near the bottom
of the tank . Thus the tank has got two parts- µtop tank¶ and µbottom tank¶

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When the transformer is in service the windings get heated up. In oil filled power transformers
oil is the cooling medium for windings. Oil is in turn cooled by means of radiators /integral
coolers with water/air as cooling medium.

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*V ONAN(Oil Natural Air Natural) cooling
*V ONAF(Oil Natural Air Forced) cooling
*V OFAF(Oil Forced Air Forced) cooling

‘  
*V Radiators used in transformer cooling are of standard profile.
 *V They are normally described in the following fashion :(example)
10-5 or 9 - 34 - 3000
10 => no. Of radiators
5 or 9 => no. Of flutes in a radiator element.
32 => no. Of elements in a radiator
3000 => distance between valve centres.

| 
*V Cooling fans are normally classified on the basis of their size like 15,18,24 or 36 inches.




*V Pumps are normally inline type.
*V Purpose is to pump oil through the transformer to create forced flow of oil.


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*V Transformers are connected in the system by any of the these methods as demanded by
our customers.
*V Over head bushings
*V Cable boxes
*V Bus duct
*V A combination of above

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High voltage, low voltage and in some cases third winding ³tertiary´ or ³stabilising´ leads are
brought out through bushings. They are called hv bushing, lv bushing and tertiary bushing. These
bushings can be mounted on the tank cover(or topmost horizontal plane in the tank) or in some
cases some bushings are mounted on vertical end walls

  
*V In sites where customer has laid cables instead of overhead conductors the termination
(connection) is through cable boxes.
*V Cable boxes are enclosures attached externally to the transformer tanks.
*V They can be on the lv wall,hv wall or on both lv and hv walls. Similarly instead of walls
they can be attached on the cover also.
þ

*V Generator transformer primary is connected to the generator through bus ducts.
*V For bus duct connections bushings are brought out through cover or through
independent/common turrets.
*V These bushings are enclosed circumferentially by hoods which in turn receive the busduct
flange.
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—V It¶s purpose is to add or subtract turns from the main coil.
—V It is housed inside the transformer tank (except ctr oltc). These are the standard products
and based on the variant in use their dimensions are known in advance.

£ V þ
  
—V When oil in the transformer tank expands some room for this expansion is required. This
is provided by the conservator,which is a cylindrical vessel placed above the transformer
tank.
—V Because of any internal fault heat is generated which decomposes oil and insulation
material resulting in the formation of gases. These gases rise up and while approaching
the conservator passes through the buchholz relay
—V Buchholz relay is a protective relay .When the accumulation of the gases rise above a
certain level then the float in the buchholz relay rises activating a mercury switch which
gives the alarm
—V When the gas accumulation is still higher then another float activates the trip switch
disconnecting the transformer from the circuit.

[ V  
  
—V Moisture is an enemy of transformer insulation system
—V Whenever oil contracts transformer breaths in through breathers.
—V With air lot of moisture which is present in the air also go inside.
—V The silica gel present in the breathers absorb moisture and only dry air goes inside.
—V After a certain level of absorption the color of silica gel crystals change from blue to pink
when these particles should be recharged or replaced.

0 V  
—V A conservator is a cylindrical vessel which provides space for expansion of oil inside the
transformer or supplies oil to the transformer when the transformer oil cools and
contracts in volume.
—V A conservator is always placed above the transformer
—V When the conservator is used for the main transformer it is called main conservator and
when it is used for the oltc it is called auxiliary or oltc conservator.
 
 c 
hc 
Shunt reactors find application in long EHV Transmission lines to overcome overvoltage
problems introduced due to high capacitive charging current and control dynamic over-voltages
under switching-in/switching-off conditions.VDuring normal operation of an electrical power
system, the transmission and distribution voltages must be maintained within a small range,
typically, from 0.95 to 1.05 pu of rated value. Due to the load variations, shunt reactors and
capacitors have been applied in power systems to compensate excess reactive power (inductive
for heavy load conditions, and capacitive for light load conditions). Shunt reactors are commonly
used to compensate the capacitive reactive power of transmission and distribution systems and
thereby to keep the operating voltages within admissible levels.

The need for large shunt reactors appeared when long power transmission lines for system
voltage 220 kV & higher were built. The characteristic parameters of a line are the series
inductance (due to the magnetic field around the conductors) & the shunt capacitance (due to the
electrostatic field to earth). An equivalent diagram for a line is show in the figure below.

Both the inductance & the capacitance are distributed along the length of the line. So are the
series resistance and the admittance to earth. When the line is loaded, there is a voltage drop
along the line due to the series inductance and the series resistance. When the line is energized
but not loaded or only loaded with a small current, there is a voltage rise along the line (the
Ferranti-effect)

In this situation, the capacitance to earth draws a current through the line, which may be
capacitive. When a capacitive current flows through the line inductance there will be a voltage
rise along the line.

To stabilize the line voltage the line inductance can be compensated by means of series
capacitors and the line capacitance to earth by shunt reactors. Series capacitors are placed at
different places along the line while shunt reactors are often installed in the stations at the ends
of line. In this way, the voltage difference between the ends of the line is reduced both in
amplitude and in phase angle.

Shunt reactors may also be connected to the power system at junctures where several lines meet
or to tertiary windings of transformers.

Shunt reactors contain the same components as power transformers, like windings, core, tank,
bushings and insulating oil and are suitable for manufacturing in transformer factories. The main
difference is the reactor core limbs, which have non-magnetic gaps inserted between packets of
core steel.

3-phase reactors can also be made. These may have 3- or -5-limbed cores. In a 3-limbed core
there is strong magnetic coupling between the three phases, while in a 5-limbed core the phases
are magnetically independent due to the enclosing magnetic frame formed by the two yokes and
the two unwound side-limbs.
The neutral of shunt reactor may be directly earthed, earthed through an Earthing-reactor or
unearthed.

When the reactor neutral is directly earthed, the winding are normally designed with graded
insulation in the earthed end. The main terminal is at the middle of the limb height, & the
winding consists of two parallel-connected halves, one below & one above the main terminal.
The insulation distance to the yokes can then be made relatively small. Sometimes a small extra
winding for local electricity supply is inserted between the main winding & yoke.

When energized the gaps are exposed to large pulsation compressive forced with a frequency of
twice the frequency of the system voltage. The peak value of these forces may easily amount to
106 N/m2 (100 ton /m2). For this reason the design of the core must be very solid, & the
modulus of elasticity of the non-magnetic (& non-metallic) material used in gaps must be high
(small compression) in order to avoid large vibration amplitudes with high sound level
consequently. The material in the gaps must also be stable to avoid escalating vibration
amplitudes in the end.

The loss in the various parts of the reactor (12R, iron loss & additional loss) cannot be separated
by measurement. It is thus preferable, in order to avoid corrections to reference temperature, to
perform the loss measurement when the average temperature of the winding is practically equal
to the reference temperature.

Air-core shunt reactors are applicable to system voltages up to 72,5 kv and typically they are
connected to tertiary winding of large power transformers. Due to the required ratings, the ACR
for this application are designed in ¿berglass encapsulated technology.

In ¿berglass encapsulated technology, the reactor¶s winding consists of numerous insulated

aluminium conductors connected in parallel. These conductors are mechanically immobilized
and encapsulated in epoxy impregnated ¿berglass ¿laments forming cylinders. Depending on the
reactor¶s ratings, one or more of these cylinders are connected in parallel between the aluminium
spiders. The individual cylinders are separated by ¿berglass spacers, which form the cooling
ducts of the coil.

The benefit in using air-core shunt

Reactors are:

> Maintenance free and environmentally friendly

> Conservative temperature rise for extended service life
> Customized space saving solutions for installation in
Compact areas
> Surface treatment for protection against UV radiation
And pollution
> High mechanical strength to withstand elevated
Short-circuit forces
> Low noise level for sensitive applications
Shunt reactors are a vital part of the efficient operation of long transmission high voltage power
lines.

The shunt reactor compensates the capacitive generation on power lines to avoid non-controlled
voltage rise especially on lightly loaded lines. The simple design and robust build-up makes the
shunt reactor the most cost efficient mean to compensate the capacitive generation.

One of the reactor designs is based on the gapped core concept, which gives a compact design
with low losses and low total mass. The concept was introduced in the mid nineteen sixties.
Today the reactor has become a high tech product requiring special skills in both design and
manufacture.


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:
1.V #'() ))- when single phase reclosing is required in the system,
it is desirable that Shunt Reactor should have maximum Zero sequence impedence in
addition to neutral reactor. This property in shunt reactor depends upon the core
arrangement
2.V 
 h' )'* !!- low loss reactors have been developed
by adopting epoxy encapsulated radially laminated core packets

3.V ) 
# !#- as a part of transformer winding design disc winding for low
voltage reactor and interleaved disc winding for high voltage reactor is followed. High
voltage reactor windings are generally in two parallel groups with line terminal at the
centre. Eddy current loss is minimised by adopting strand wire dimensions and use of
bunched wire cables
4.V 
#!! ! 
)##)+# ,- special flux
plates which also act as winding press plates are provided at top and bottom of winding to
collect the leakage flux, thereby minimising stray losses in tank and eddy current loss and
consequent hot spot at the end discs of winding
5.V !!" 
)#&
!- - ceramic spacers having high
modulus of elasticity are used to form gaps between core packets. Special tightening
arrangement is given to provide dead solid support across the gap. The fundamental
mechanical resonance mode of reactor frame is kept away from twice the power
frequency using computer program.
6.V 

+)-- welding is done to tighten the tank parts firmly so that they can bear
the heavy vibrations during reactor operation. This is also done to eliminate the
possibility of leakage. The fundamental mechanical resonance mode of reactor frame is
kept away from twice the power frequency using computer programme.

 
 c
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The Ultra High Voltage laboratory at BHEL, Bhopal the premier laboratory of its kind in India,
offers most modern and sophisticated testing facilities for a wide range of transmission
equipment and products. The laboratory is designed essentially for the comprehensive testing of
power transformers and shunt reactors. The impulse test plant and AC high voltage test plant are
adequate for test levels appropriate up to 1100kV transmission systems. The AC power test plant
is presently suitable for performing test on equipment up to 800kV class with provision of
enhancing the capacity in future for conducting tests on 1100kV equipment. The DC test plant is
adequate for test levels suitable up to +/-800 kV HVDC transmission systems.

With the above facility, performance testing of 315 MVA 3-phase transformers; 200 MVA
single-phase converter transformers; 80 MVAR shunt reactors for 400 kV AC system, 315
MVA, +/- 500 kV DC single-phase converter transformers and 800 kV bushings and CVTs have
been satisfactorily established in the laboratory.


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UHV laboratory is one of the largest electro-magnetically screened laboratories in the world,
attached to a transformer manufacturing plant. The major test equipments are mobile on air-
cushion transport system, which provides flexibility of placement of test objects and test
equipment in the hall with no space constraint up to the highest test voltages.




—V All double wall GI construction with electrical continuity, false roofing and embedded
earth copper mesh provides a complete Faraday cage (electromagnetic shielding).
—V Acoustic attenuation with reverberation time of 3-3.5 seconds in the desired frequency
range.
—V Low impedence grounding system.
—V Special floor for smooth air-cushion transport.
—V Air cooling and ventilation system to control ambient variations during temperature rise
tests.
—V Discharge-free halogen lamps for illumination.

  


A pollution test chamber is located adjacent to the main test hall for conducting wet and
pollution tests. Voltage to the test object in the pollution chamber is applied from the main test
hall through a 750kV wall bushing. A 100MVAr, 156kV, 3-phase capacitor bank with provision
for augmentation up to 120MVAr enables conducting a load loss measurement and temperature-
rise test on transformers and reactors.

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—V Impendence, loss and temperature rise tests

—V Separate source voltage withstand test
—V Induced over voltage withstand test
—V Partial discharge measurements
—V Lightning impulse full and chopped wave tests
—V Switching impulse tests
—V Other routine and type tests

Special test on reactors

Vibration and stress measurement and measurement of magnetisation characteristics.

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!*'#)!

—V Long duration DC voltage test

—V DC polarity reversal test with partial discharge measurement
—V Temperature rise test with DC voltage supply
—V Lightning and switching impulse tests
—V AC power frequency test
—V Loss measurement

c!!&!'#!

—V Tan-delta and Capacitance measurements

—V Partial discharge and RIV measurements
—V Dry and wet power frequency dielectric tests
—V Lightning and wet switching impulse tests
—V Thermal stability test
—V Dielectric tests with DC application
—V Snap back test

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#!*!

—V High-resolution impulse analysing system

—V Digital power analysers
—V Partial discharge detectors
—V RIV meters according to CISPR
 —V 12 channel U-V recorder
—V Three-phase and single-phase ratio meters
—V Bridge for winding resistance measurement
—V Bridge for loss tangent and capacitance measurement
—V Bridge for inductance and loss measurement
—V Digital insulation testers/meggers
—V Double beam impulse oscilloscopes
—V Digital storage oscilloscopes
—V Inductance and high-frequency impedence analysers
—V Precision AC and impulse digital peak voltmeters
—V Precision ammeters, voltmeters and low power factor wattmeters
—V Aqua-test set for moisture content measurement in oil
—V Liquid dielectric test set
—V Resistivity cell and conductivity meter

)")!*!"!)'


- *

—V Signal averager and ultrasonic transducers for location of corona leak detector
—V Recurrent surge generator and high frequency oscilloscopes for low voltage impulse
studies
—V Infra-red thermovision system for temperature scanning during electrical tests
—V High power binoculars and photographic equipment for recording of corona discharges
—V High frequency impedence analysers
—V 14 channel magnetic tape recorder