Prepared by:

Jimit Dhruv

Elect.Engg,Dept.

Valiya Institute Of Technology-Valiya

Introduction
Core material:
Basic material are Alloy Steel having main

content Silicon & carbon

Which increases permeability & reduces losses

 HRS:
HRS not used now a days
As it has random direction &hard to measure

Magnetic properties

CRGOS:
CRGOS shows excellent Magnetic properties
So CRGOS is more used

Core construction
Due to Pulsating flux, core should be

laminated
Transformer of larger size may forms in
cut C or cut E type.

Types of Interleaving:
I.
Simple Interleaving
II. Meter core Interleaving:

45
2) 33 /55 overlapping
In 3- Shell type transformer middle
winding is reversed
If not then 73% more core is used
which leads in increase in over all cost
1)

Transformer winding

Concentric
Sandwich
Spiral: It is used 100

A& for low Voltage

Winding
Mechanically very

strong

Helical :Intermediate

range of current
Suitable for LV winding

of large transformer

Cross-over: suitable of

current not exceeding 20

A
Use for HV winding of

small transformer

Continuous disc: no of

turns wound radially over

one another
separated by spacers
HV winding
Mechanically strong

Sandwich: mostly used

for shell type transformer

Control leakage

reactance
HV & LV are near so
leakage flux is reduced
mmf of each section is
same.

Insulations
Two main kinds of Insulations:
1. Major Insulation:
Insulating cylinder between LV & core
Also between HV & LV
Insulating barriers between limbs, coils & core
yoke
Oil impregnated paper used as it has high
dielectric strength
2. Minor Insulation:
Insulation between
individual turns & between layers
Conductor Insulation: paper&cotton
Air insulated Transformer
insulation used is glass tap

Bushing
Up to 66kv non-condenser bushing are used is

porcelain & oil filled

Above 66kv condenser bushing are used for

economic reasons.
Condenser type bushing: It is formed by

inserting Aluminum foiled layers into a paper

winding at predetermined radius.
Partial capacitance
In outdoor substation the

bushing are covered by a

porcelain rain shade

Tapping
Main two location:
1. Inside Tank
2. Outside Tank
Considered as integral part of transformer

Tapping operation
(1)On load
tap changer

(2)Off load
tap changer

Tapping is terminated just bellow oil level

External handle
Taping is done on HV winding

Provided in middle (axial & radial force)

Transformer Tank
Plain sheet steel

Tank
Tube Tank
Corrugated Tank
Radiator Tank
Tank with separate
coolers

Conservator
What is Conservator ?
The expansion of oil from Transformer

tank takes up in Conservator

When oil contracts, air from

atmosphere enters in Conservator .

Risk of contamination of oil in transformer
Breather valve is mounted to avoide

moisture
Breather contain silica in it

Buchholz Relay
Operation:
Gas operated relay
AT the time of fault to maintain the continuity

of the supply
Fault detected particularly in incipient stage ,
major fault can be avoided
Which is placed between conservator
and transformer tank

Transformer oil
Double purpose :
ie cooling & Insulating
Permittivity is 2.5

As per I.A.S breakdown strength of oil

used must be 50kv RMS

Major disadvantage is sluging
To overcome this, synthetic oil is prefered
One of the e.g is Chlorinated dephenyl is a

synthetic oil its permittivity is 4.5

WORKSHOP(TPT DEPT.)
WINDING SHOP
CORE & ACTIVE PART
FINAL ASSEMBLY
QUALITY TEST
FINAL TESTING

WINDING SHOP
TYPES OF WINDING
NORMAL WINDING
ii. INTERLEAVE WINDING
iii. TERITARY WINDING
i.

ROTARY
HORIZONTAL

HELICAL

KTRANSPOSITION
TYPE

MACHINES
VERTICAL

CONTINUOUS
DISC

End Rings & shielding for prevention purpose

 Conductor Insulation:
Precompressed press board insulation(CRIP
PAPER)
2. Craft paper
3. Also spacers as insulation
1.

Moisture Control

Winding Auto Clave: Uses temp. of 110

C to 130 C and Vacuum of about 0.4 to
0.5 mbar.
Insulating Oven : Uses Heating Only

Pressure Machine
Brazing Machine with use of SILPHOS
ALLOY
Post Insulation

 PROCEDURE:

CORE & ACTIVE

PART
ACTIVE PART
C.R.G.O. STRIPS
1-STRIP HAS WIDTH OF 0.27 mm
COIL OR WINDING ASSEMBLY
PROCEDURE:
Manufacturing of LIMB
Core Insulation
Removal of TOP FRAM for Coil assembly
Winding insulation detail
TOP YOKE FILLING
VAPOUR PHASE OVEN
HV & LV leads from top & bottom to the bushings
REGULATING COILS to the tap changer

FINAL ASSEMBLY
Installation of active part and assembly of

accessories
TRANSFORMER TANK

BELL TYPE

JOINED AT
BOTTOM
SIDE

CONVECTIONAL
TYPE

JOINED AT
UPPER
SIDE

 ACCESSORIES:
Blanker : Leakage of oil & Radiators

adjointment
Buchholz Relay: To trip the transformer
OSR (oil serge relay): To indicate the level

and quality of oil

MOLG(magnate oil gage): It indicates the

level of oil in the conservator

Breather Valve: Provide dry air using silica

gel and have air seal of neoprene

Cooling Equipment: Generally for cooling
of oil in a tank
1.

2.

Radiators
Thermosyphan

 Method of Cooling:
ONAN
ii. ONAF
iii. OFAF
iv. For very high temp using HEAT
EXCHANGER
i.

CT(Current Transformer):Two
purposes;
1.
2.

Winding temp indicator (WTI)

Oil temp indicator (OTI)

BUSHINGS: The leads from top and

bottom of the winding are brought out to a
length of few cm only and the outdoor
terminal of the transformer are provided
by bushings

 PROCEDURE
Vacuuming of Tank(up to 0.3 mbar) for about

24hrs to 36hrs
The Leak Rate Test with the use of water & air
Oil Test which includes BDV & PPM
Oil Filling
After the IMPREGNATION TIME the whole

accessories are to be attached.

QUALITY TEST
ANALYSIS WITH SIGMA CARD
Sigma card includes below required data
Design
Process Time
M/C size specification
Process of manufacturing
Dimension specification
Testing specification
Information about control points

FINAL TESTING
ROUTINE TESTS

TYPE TESTS

NO LOAD TETS

TEMPRETURE
TEST

LOAD LOSS
INSULATION
TEST

IMPULSE TEST

CAPACITANCE &
TAN

SEPARATE
SOURCE

INDUCED OVER
VOLTAGE

WINDING TEST

VOLTAGE RATIO

ZERO SEQUENCE
IMPEDANCE
TEST

HARMONIC AND
NOISE LEVEL
TEST

CT (CURRENT TRANSFORMER)
Generally CT is use for the below four

purposes:

Measurement of Current
Measurement of Power
Isolation between High voltage and Low Voltage
Inputs to Relays & Protection Systems

PROCEDURE OF CURRENT

TRANSFORMER:

CO NDUCTORS USES :ALUMINIUM OR

COPPER(HIGH CURRENT RATING)

In the manufacturing of the primary winding or

protection core there will be the creation of the

capacitance as below.
GRADING & SUB GRADING.
MAIN GRADING HAS WRAPPED

ALUMINIUM FOIL & CRIP PAPER

AT 300MM DISTANCE PERFORATED ALU.
FOIL (400MM) AND CRIP PAPER.
SIMULTANEOUSLY INSULATION MAKE
CAPACITANCE

 Quartz in CT
Reduces the quantity of oil
Provides mechanical strength for the

conductors
Improves the quality of oil by absorbing
moisture
Being a bad conductor of heat, it allows slow
heating /cooling of the CT.
Finally expansion tank is attached and after
that evacuation of oil and gas filling will be
there .
There is also one imp term is D3 point which
is also called the earth point.

Thank You