Winding Construction _

Transformer windings are designed to meet three fundamental requirements, Viz. mechanical, thermal and electrical. They are cylindrical in shape and are assembled concentrically. Paper insulated conductors of high conductivity & soft drawn E.C. Grade copper is used which comply with the latest Indian as well as international Standards. Windings are made with great care by well experienced techno-crafts man in dust free & temperature controlled environment. Insulation between layers and turns is based upon the electrical and mechanical strength level. Interlayer cooling ducts( Axial & Radial) are provided to minimize the temperature gradient between windings and oil, and hence the hot spot temperature is kept to a minimum. This also ensures that the rate of insulation deterioration is minimized and high life expectancy is achieved. Transpositions are made in multiple conductor windings, to ensure uniform current distribution ,to minimize circulating currents ,to decrease eddy current loss and improvement of the lamination factor. Helical/Layer windings are most suitable for low voltage windings of large power transformers to mitigate high current design requirement . For High voltage windings the disc coils with excellent mechanical strength are used to take the stresses due to voltage level. Special interleaved or shielded construction offers most uniform voltage distribution despite system transient. Specialized disc winding and inter-leaved disc windings are used having very high series of capacitance giving a very good impulse voltage performance.

Core Assembly _
Core is built with Cold Rolled Grain Oriented Silicon Steel, low loss silicon steel lamination . Bonded core design/ technique is used to eliminate hole punching and to minimize fixed losses and Magnetizing Current. Use of HiB grade & Laser scribed Laminations and Rigid clamps significantly reduce vibrations and noise level. Cooling ducts are provided in large transformers for efficient circulation of oil to keep temperature of core well within

limit without affecting the flux distortion and also in the core suitable insulation paper are inserted between some laminations for the purpose of reducing eddy currents and also minimizing magnetic short circuit. The steplap or Mitred joints at the core corners ensure a stream line magnetic flux path. The core limb are held with resin bonded glass bands to eliminate limb bolts. Yokes are clamped by solid mild steel plates with yoke stud ensuring high rigidity for withstanding mechanical socks during transportation & Short Circuits. The leg core in a which hard wooden bars are inserted, are tighten with synthetic resin impregnated glass bend.

CCA & Connection Process _

L.V. Windings are normally placed near core over insulating cylinder and oil ducts. HV Windings are assembled co-axially placed with respect to LV. Spacers between coils are 'T' shaped for added firmness. Coils are assembled with best insulating materials and are adequately clamped. SPA methodology is now a day widely adopted to have its special beneficial characteristics. The winding is rigidly supported by a common spacer ring of densified wood at the top and bottom for precise alignment. Well profile angled rings are placed between LV & HV windings to reduce voltage stress level. The ends & tapping leads of all windings are connected by special extra flexible, insulated copper cables which are rigidly braced in position.

Tapping Device Assembly _

Generally Taps are provided on HV Windings for HV Variation or LV Variation as specified by customer. These are brought up to a gang operated switch, suitable for external manual operation and can be locked in any desired position to avoid unauthorized operation. All the moving contacts are spring loaded to ensure proper pressure and good contacts.

To achieve precise voltage regulation On load tap changer is used instead of OCTC. Usually Higher capacity transformers i.e above 3000 KVA ratings, can be supplied with On Load Tap Changer along with necessary controls to make it suitable for manual, local electrical or remote Electrical operation

Tanking & Erection process _

Dried out CCA very first proceed for tightening before application of hot Oil shrinkaging for 24 hours. The oil shrinkaging process avoids looseness of active parts during its service at site. At last uniform pressing is done on CCA. High mechanical rigidity is achieved by hydraulic pressing at circulated force and tightening all pressure screws. Pressed CCA is put in to the tank with proper locating & locking arrangements which is prime important to achieve high resistivity against transient damage ,vibration during service and Forces develop during fault occurrence. The dried CCA is boxed up in pre fabricated MS tank. After completion of CCA insertion in tank, hot, degassed oil is then allowed into the transformer tank under vacuum. This oil is then circulated through the transformer and the oil degassing plant until all gas trapped in the core, windings, and the insulation is removed. This ensures a high degree of stability in the insulation structure and early attainment of its mature condition, which would not otherwise be achieved until the transformer had been in service for some time. The transformer is made ready for testing after assembly of bushings , conservators, radiators & all other protective devices .All the joints are gasketed to avoid leakage with the help of rubberized cork sheets/Nitrite Rubberized O-Ring , which can withstand high oil temperature and do not deteriorate nor contaminate oil in its contact. Short Circuit withstand capability is always stand as a big challenge for any designer. In order to prevent deformation when subjected to short circuit forces, the windings are axially and radially supported. Solid block end insulation, adequate number of spacer rows and anchoring and bracing tapes, backed-up by substantial supporting frames are utilized. The axial end thrust under fault conditions is minimized by the suitable distribution of ampere turns over the length of the windings, and by ensuring that the design dimensions are closely adhered to during manufacture.

Drying Process _

For transformers up to 33 KV, drying is carried out in well ventilated, electrically heated oven for a period determined by electrical tests. The transformers are then immersed in freshly filtered hot oil and allowed to stand for a period until all trapped air is escaped. For transformers with voltages of 66 KV and above, drying out treatment takes place in a vacuum drying oven. The core and windings assembly is placed in oven and initially heated at 90C for some time. During this period, heated air is circulated rapidly and the moisture laden air is bleed off at frequent intervals. Vacuum is then applied, and heating of the core and windings assembly is continued simultaneously. The mixture of air and moisture that is extracted is passed through a condenser and collected in the form of water which is measured and recorded. The end point of drying process is decided by the measurement of insulation resistance, tan-delta, and the collection of water. For bigger transformers, 25 MVA and above, Core coil assembly along with tank are in the oven and after completion of heating cycle, hot, degassed oil is then allowed into the transformer tank under vacuum. This oil is then circulated through the transformer and the oil degassing plant until all gas trapped in the core, windings, and the insulation is removed. This ensures a high degree of stability in the insulation structure and early attainment of its mature condition, which would not otherwise be achieved until the transformer had been in service for some time. The core- coil assembly is placed in Vacuum Auto Enclave to eliminate moisture content which is targeted less then 0.5 % moisture. Drying process is to be carried out @ 90C & respective vacuum cycle at rated interval to improve Insulation resistance and remove ingress of moisture in insulation material..

Tank Fabrication _
Protection of active part in transformer is very important. While achieving the optimized size of transformer to suit the site condition for installation. The main role of the tank is to protect the active part and tank is manufacture to have sufficient strengths to withstand internal & external faults that may occur during operation. Tanks are fabricated from low carbon M.S. Sheet of best quality proceed by qualified welders. The tank is designed to withstand vacuum and pressure test as per national/ International standards. A robust

skid under base is provided, and guide bars are located inside the tank to securely fix the core and windings assembly in position, and to prevent any movement during transportation. Welding is done as per ASME section lX by qualified welders as per approved WPS and leak test assured 100 % leak proof seams and maximum mechanical strength. During fabrication process ,welding quality is assessed by DP test. Completed tank fabrication is followed by shot blasting process to remove all dust & spatters before painting.

Final Fitting with All Accessories _

All the standard fittings conforming to respective standards are provided on each transformer. In addition to this the following optional accessories, wherever applicable, can be provided if ordered:

Oil Temperature Winding Temperature Indicator Double Float Buchholz Relay Magnetic Oil Level Gauge Pressure Relief Valve / Explosion Vant Disconnecting Chambers for Cable Box Heat Exchanger/ Radiators Oil & water circulating Pumps

Flow Indicators & Differential Gauge RTCC panels (With & Without AVR) & MK Box Drain/Filter/ Sampling/radiator Valves Bushings & accessories Bidirectional Rollers Silica Gel Breather Conservator Tank

HT & LT Winding Termination _

Terminals to suit Customer's requirements can be provided. Outdoor bushings are normally provided for the HV & LV terminals. HV outdoor bushings are supplied with arcing horns as standard. Air insulated and compound filled cable boxes, with or without disconnecting chambers, can be provided to suit customer's specification. The terminals of

our transformers can be made suitable for heat shrinkable cable termination system.

Painting _
Metal which has been pre-treated by means of shot blasting to remove rust and welding scale is thoroughly cleaned, and then a coat of epoxy zinc chromate primer paint is immediately applied to all external surfaces. This anticorrosive primer has rust inhibitive properties and excellent chemical resistance. Two coats of Epoxy or PU paint , which is highly resistant to chemicals and oil, are then applied. Inside surface of the tank is applied with HOR paint.

Oil Filling & Filtration _

All the Transformers are supplied with first filling of oil conforming to IS 335. Before filling, oil is heated, filtered and vacuum treated in filter machine to remove any foreign particles, moisture and air.

Testing _
Before dispatch each and every transformer is subjected to all routine tests as specified by IS/IEC/BS/ANSI standards. The company has fully equipped test laboratory for conducting all routine tests and temperature rise test in accordance with national & International Standards.

Arrangement can also be made to carry out relevant type tests, if required, at recognized laboratories. Transformers up to 20MVA, 66kV c lass are Short Circuit, Impulse tested , while 31.5 MVA,220 kV and 60MVA, 132/33kV transformers are impulse tested at nationalized laboratories like CPRI,ERDA etc which stands us as a reputed & quality transformer manufacturer. In addition to the normal routine test facilities, the following measure type test facilities are available in house as per national/international standards.

Partial discharge test Noise level measurement Temperature rise test setup Harmonic measurement & analysis SFRA Test Tan delta and capacitance measurement

Dispatch _
Main body of transformer is covered by polyethylene sheets while other loose accessories are shipped in standardized seaworthy wooden packing boxes with ship marks and contents specified for damage free shipment. Many of transformers are dispatched with VCI packing looking towards the climatic condition of ultimate customers destination. Shipment takes care of balancing of the weight while loading the transformer on to the transport vehicle. Proper welding is done on the base so that there is no scope of vibrations during transportation irrespective of quality of roads.
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Vacuum Drying Plant and Vacuum Impregnation Plants

Drying and impregnating systems are principally used for processing paper-insulated components such as transformers, and other electric components. In this process, the residual moisture content in the paper is to be reduced to a minimum under vacuum. After drying, the components are impregnated by filling or flooding it with insulating liquid. The Hot Air is circulated in Autoclave under Vacuum. The material is initially heated by hot air circulation at atmospheric pressure, and then the material is heated under vacuum using radiation. This process removes most of the humidity along with heating the object so that sufficient heat is stored in it to evaporate the balance moisture content. Impregnating systems are used in the production of motors, generators, transformers and coils. The components are degassed and prepared in the tank. Then they are impregnated by flooding them with insulating medium. DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD

Polarization Index Test

Polarization Index Test is the variation of insulation resistance. It is the ratio of insulation resistance after ten min to the insulation resistance after one minute. In polarization index test leakage current is measured by applying a direct voltage between the windings and the equipment or machine. The Polarization Index (PI) readings are noted for the equipments, normal Polarization Index value indicates good insulation. Too high or low values indicate that the machine is contaminated and hence the insulation has to be cleaned.

We are one of the well known company in India for providing wide range of services for testing various equipments like Turbines, Generators, HV Motors, Transformers, Switchgear, Surge Arrestors, Power Cables, HV Bushings, CTs, CVTs, etc. in Power, Distribution, Industry Sectors and also Refineries. Polarization index testing is widely used for testing the level of insulation in various machineries and equipments. This test helps in determining whether the insulation is clean and free from moisture.

Partial Discharge Testing

Powertest Asia Private Limited is one of leading company in India for providing a wide range of services for partial discharge testing. Partial discharge testing is done for checking the electrical breakdown or insulation capacity in devices due to high pressure of voltage. Partial discharge in equipments affects the insulation and indicates breakdowns. These discharges can occur in insulators that contain gaseous inclusions, cavities, or voids.

We use different types of Partial Discharge Measurement devices for performing this test. PDA Couplers and TVA probes are used for detecting partial discharge in generators and other equipments. Partial discharge testing carried out by us accurately specifies the poor condition of insulation and thus reducing the failure of the equipments. This test can be conducted in normal operating conditions.

Partial discharge testing does not affect the equipment under test and most of the times the occurrence of partial discharge can be identified within the test object, thus allowing the solving of the problem. The Partial Discharge Measurement analysis are used to predict the electrical equipment which needs to be repaired. This test is widely applicable for testing insulations of cables, rotating machines like turbines, generators, transformers, gas insulated switchgears etc.