INTRICACIES OF

TRANSFORMER
MANUFACTURIN
G

MAJOR COMPONENTS

CORE

WINDING

DIELECTRIC

TANK

CORE

LOW RELUCTANCE CRGO MATERIAL FOR HIGHER COEFFICIENT

OF COUPLING AND LOW IRON LOSSES.
EX. 1)M4 1.3 WATTS/KG 2) MOH - 1.03 WATTS/KG 3)ZDK - .85 WATTS /KG

CORE LAMINATION THICKNESS OF .23/.27/.30 mm.

0.006 mm CARLYTE INSULATION(SUSTAINABLE UPTO 1100 deg C) IN EACH

LAMINATED CORE.

USE OF LASER SCRIBED CORE STEEL TO AVOID BURS ABOVE

30 MICRONS AND REDUCE LOSSES

STEPLAP CORE CONSTRUCTION WITH MITERED JOINTS FOR MECHANICAL

STRENGTH ,HIGHER BIULDING/STACKING FACTOR
AND PERPENDICULARLY DIRECTED FLUX DISTRIBUTION
(TO AVOID INGRAIN AND CROSSGAIN LOSSES).

STEEPER B-H CURVE FOR TO AVOID SATURATION AND

OVER FLUXING CONDITIONS (CONTINUOUS FOR 110% ,
1 MIN. FOR 125% AND 5 SECONDS FOR 140% OF RATED VOLTAGE )

ABILTY TO SUSTAIN GEOMAGNETIC DISTURBANCES WITHOUT

SATURATION OF THE CORE.

USE OF NON MAGNETIC STEEL FOR CLAMP PLATES AND ELIMINATION

OF YOKE BOLTS IN HIGHER CAPACITY
TRANSFORMERS FOR REDUCED STRAYLOSS ,
IMPROVED INSULATION.

USE OF BOTTON SPACERS IN CORE FOR BETTERR SPACE FACTOR

AND OIL FLOW.

WINDING

 ENAMEL PAINTED ELECTROLYTIC GRADE COPPER

TYPE:
1) PAPER INSULATED COPPER CONDUCTOR
2) CONTINUOUSLY TRANSPOSED CONDUCTOR
MECHANICAL STRENGTH ,SPACE FACTOR,
VOLTAGE CLASS AND TYPE OF WINDING
DECIDES THE BASIS OF CONDUCTOR
SELECTION.
HELICAL AND SPIRAL WINDINGS ARE
PREFERRED FOR LV WINDING.
DISC WINDING WITH INTERLEAVING/CROSSOVER
IS PREFERRED FOR HV WINDING.
USE OF CLAMPING INSULATING RING (UDL WOOD)
FOR OPTIMIZATION OF AXIAL CLEARANCE

 OPTIMIZATION OF RADIAL
CLEARANCES THROUGH
SYMMETRICAL
STRESS DISTRIBUTION.
INTERLEAVING OF WINDINGS
INCREASES ITS MECHANICAL
STRENGTH AND IMPULSE/S.C
WITHSTAND CAPABILITY.
PROPER TRANSPOSITON OF
CONDUCTORS FOR REDUCING
CIRCUATING CURRENTS AND
EDDY LOSSES.
WIDTH THICKNESS 6 OR
ELSE EDDY CURRENT LOSSES
WILL BE 150%.
IMPROVED INTER TURN
INSULATION AND COOLING
THROUGH THE USE OF
T-SPACERS.

DIELECTRIC

Types of transformer Oil:

Paraffin based transformer oil
Naphtha based transformer oil
Naphtha oil is easily oxidized but the sludge in the naphtha oil is
more soluble than Paraffin oil. Thus it does not disturb the
transformer cooling system.
Class A insulation CRAFT PAPER,PRESS BORD,UDL WOOD is
used as solid insulation.
The velocity of oil should be limited to 1m/sec to avoid STATIC
ELECTRICITY DISCHARGE which may be destructive for
transformer health.
Using dielectric modelling(widman curve),solid insulation is
provided at specific positions to improve the withstand capability of
oil insulation.(as mobility of oil decreases its withstand capability).
Using moulded insulation to avoid unequal field distribution having
sharp corners and uneven spacing.

 Zone A:
Nearly uniform field.
The number and the thickness
of the barriers are decided by
the stress withstand of the
oil gaps.

Zone B:
Non uniform Field .The oil gaps
are larger than in Zone A. The placements of
barriers and static rings are critical to make
the field more uniform.
Zone C:
Most important from Insulation design consideration.
Zone of high gradients and is subject to both puncture and surface
creep stresses.

BUSHING & OLTC

FOR DIFFERENT POLLUTION LEVELS

POLLUTION LEVELS

CREEPAGE DISTANCE

I. Light ( areas without industries,

16 mm/kV

agricultural or mountain areas )

II. Medium ( areas with industries

20 mm/kV

not producing pollution smoke,

Low density of house areas not exposed
to the coast)

III. Heavy (Areas with high density of

25 mm/kV

industries, high density of

Heating plants producing pollution,
areas close to the sea.)

IV. Very Heavy (Areas close to

31mm/kV

the coast and exposed to sea spray,

desert areas, areas exposed to strong
winds carrying salt and sand etc

Example: for 145 kV Bushing with heavy pollution level minimum creepage
distance works to be.
145 kVX 25mm/kV = 3625mm

This is provided at the oil side of

the bushing to control the
electrostatic field inside the
transformer after installation

+
-

+
-

Basic Arrangements of Tap Windings

U1

U1

U1

U1

U2
U2

U2

U2

OLTC ON AUTO-CONNECTED TRANSFORMERS

OPERATING SEQUENCE OF TAP SELECTOR &

DIVERTER SWITCH

Tap Selector
Operation

Diverter

Switch
Operation

SCR

OLTC TYPE DESCRIPTION

MI 1200 60 /B-10193W
0- Linear
1W Reversing with 1 mid
position
3W Reversing with 3 mid
positions

No. of positions (05 to 35)

Insulation class of tap selector
(B/C/D)
Insulation to
ground(60/110/150/220/300)
Current Rating
(350/500/600/800/1200/1500/1800)
I-One poles suitable for 1 phase
III-One poles suitable for 3 phases(star
3/14/16
Copyright 2006 ACNielsen
connected)
a VNU business

Page 20

SCR

INSTALLATION OF OLTC WITH TRANSFORMER

FOR SIMULTANEOUS
EVACUATION OF
TRANSFORMER TANK AND
DIVERTER SWITCH COMPT A
BYPASS TUBE IS
CONNECTED BETWEEN E2 &
Q FLANGES OF OLTC HEAD.
ENSURE BLEEDING OF
TAPCHANGER HEAD VIA
BLEEDER SCREW IN THE
HEAD COVER AND PIPE
ELBOW .
AFTER OIL FILLING THE
BYPASS TUBE SHOULD BE
REMOVED .
3/14/16

Copyright 2006 ACNielsen

a VNU business

BLEEDER
SCREW

R
S
Q
E2

Page 21

Leakage Flux and stray loss control

Magnetic Field Plot without

Yoke shunt and Wall shunt

Magnetic Field Plot with

Yoke shunt and Wall shunt

Processing of Transformer
The quality of a transformer and consequently its performance
and life depends essentially on the drying process carried out
in the factory
The assembled active part of the transformer is heated in the
oven for extraction of moisture under vacuum
Proper dry out is very important else the 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.

Drying and Impregnation

The insulation system in transformer need utmost attention. The oil, paper
and pressboard insulation has to be free of dirt, dust and moisture for
obtaining the optimum insulating properties.
Moisture is injurious to insulation system since it reduces the electric
impulse voltage strength and the resistivity of the oil and accelerate the
deterioration of solid insulation.
Processing eliminates all types of impurities and foreign particles from
transformer .
During vacuum drying and oil impregnation , the gases trapped inside solid
insulation and occluded among intricate profile of insulation components
are also removed which results in low partial discharge inception voltage.
Optimal utilization of the excellent properties of oil cellulose dielectric
system depends on the efficient drying , degassing and impregnation
process adopted .

LATEST TRENDS
USE OF BIODEGRADEBALE OILS LIKE ESTER OILS
AUTOMATIC MONITORING SYSTEMS LIKE ON LINE DGA, ON
LINE PD MONITORING ETC.
FIBRE OPTIC MONITORING OF TEMPERATURES
SFRA MEASUREMENT FOR TRANSFORMERS SIGNATURE
SURFACE TEMPERATURE MONITORING BY THERMAL IMAGING
FINITE ELEMENT METHOD ANALYSIS TO AVOID
FERRRORESONACE,HARMONIC RESONANCE AND PART
WINDING RESONANCE.
USE OF DIVERTER WITH VACCUM COMPARTMENT.

RECOMMENDATION FOR VALUE

ADDITION
DURING HEAT RUN TEST ,THE MANUFACTURER
MAY BE ASKED TO CONFIRM THE OIL FLOW RATE
IS BELOW 1METER/SEC TO AVOID STATIC
ELECTRICITY DISCHARGE.
THE BUSHING CREEPAGE DISTANCE MAY BE
SPECIFIED TAKING THE POLLUTION LEVEL AND
GEOGRAPHIC CONDITION OF S/S.
THE REPORT OF IMPACT RECORDER MAY BE
GENERATED IN THE PRESENCE OF BOTH PARTIES
AS SOON AS THE JOB ARRIVES AT SITE.

THANK YOU