SUMMER TRAINING REPORT ON MANUFACTURING PROCESS OF DISTRIBUTION TRANSFORMERS AT TECHNICAL ASSOCIATES LTD.

SUBMITTED BY:Saurabh Kr.Singh 09570108051 B.Tech.7th sem

Introduction:Technical Associates Ltd. (TAL) is one of India's oldest manufacturers of Power Transformers. Established in 1967 in Lucknow, Uttar Pradesh, TAL originally manufactured Distribution Transformers for 11 kV distribution networks. Today, our scope of business activities has expanded vastly to include: 1. Manufacturing of Power & Distribution Transformers up to 132 kV. 2. Transmission & Distribution Engineering, Procurement and Commissioning Projects on Turnkey basis. Through a greenfield plant in Sitarganj, Uttarakhand TAL's transformer manufacturing capabilities are being upgraded significantly to include design, manufacture and testing of EHV Power Transformers upto 400 kV. TAL has successfully supplied more than 500,000 (approx. 40,000 MVA) transformers which are in active service across India, Bangladesh and Nepal. TAL is committed to continuous learning, product and process improvement, dedication to quality and fostering innovativeness. These are the core strengths of the company, which will allow TAL to deliver newer products and diversify into newer areas which have increasing relevance to the needs of the Energy sector. After more than 40 years in business, TAL is ready to build on it's vast storehouse of experience, expertise and excellence to play a greater role today in the development of Energy infrastructure in India, and beyond.

ACKNOWLEDGEMENT:It gives me great pleasure to express my deep sense of gratitude to Mr. Rajeev Goyal, without whose patient guidance and constant encouragement this study would not have come to its present form. I am sincerely thankful to him for permitting me to work on a topic of special interest to me for study. I owe him a debt of gratitude for constructive criticism from time to time during the course of these investigations .I am also highly grateful to other faculty members for providing all facilities for carrying out this project work. My sincere thanks must go to my family members who showed patience and forbearance during the period of our study.

Saurabh Kr. Singh 09570108051 B.Tech. 7th sem Phonics Group Of Institutions Roorkee,Haridwar 2009-13

TABLE OF CONTENT:-

1. 2. 3. 4. 5. 6. 7.

INTRODUCTION NEED OF PROJECT COMPANY PRODUCTS PRODUCT RANGE INTRODUCTION TO TRANSFORMER MANUFACTURING PROCESS CONCLUSION

HISTORY:Technical Associates Ltd. (TAL) An ISO 9001:2000 Company is known to be one of Indias oldest, reputed manufacturers of Power and Distribution Transformers. From humble beginnings in 1967 as a partnership firm; almost four decades back, Technical Associates Ltd. has today grown into a nationally respected and known Power Transformer manufacturing company.

Journey of Progress and Achievements:

1969: First order received for 5kVA, 11/0.250 kV Single Phase transformer from Uttar Pradesh State Electricity Board (now Uttar Pradesh Power Corporation Ltd.) 1970: Regular production commences of pole and pad mounted transformers of different ratings up to 1000 kVA, 11/0.433 kV. 1973: Technical Associates Ltd. registered as a company incorporated under the Indian Companies Act, 1956. 1973: Production commences at a new manufacturing facility at Ismailganj, Lucknow for Power & Distribution transformers. Ismailganj continues to be TALs head office and flagship plant for 132 kV Power Transformers. 1974: A sister concern - Sri Ram Industries set up to manufacture Transmission Line Towers. These were

designed, tested, fabricated, and galvanized for 132 kV Transmission Lines. Microwave towers up to a height of 100 Mtrs. supplied for Microwave link connecting east UP to west UP. 1979: TAL sets up the first Distribution transformer manufacturing plant in the state of Punjab in District Sangrur. 1991: TAL gets ISO 9000 certification for assembly of transformers and processing of raw materials including core laminations, slitting and cutting, conductor drawing, paper covering, transformer oil base stock processing, tank fabrication and insulation. 2001: TAL becomes a regular manufacturer of 40.0 MVA, 132 kV power transformers. 2006: TAL manufacturing activities certified for compliance with ISO 9001:2000 standards by BSI, UK. 2006: Turnkey Power Projects division set up for executing Transmission & Distribution EPC projects. 2007: TAL commences execution of several projects for Engineering, Procurement, Construction, Erection and Commissioning of Switchyards for 33, 66 and 110 kV switchyards and Lines from 11 kV up to 132 kV all over the country. 2007: Work commences on setting up a state of the art manufacturing plant in Sitarganj, Uttarakhand for manufacture of Extra High Voltage Power transformers

up to 400 kV class. 2008: State of the art plant commissioned at Sitarganj (Uttarakhand). It will enlarge TALs transformer product portfolio to include EHV Transformers up to 400 kV; a quantum leap in manufacturing and technology. TAL has successfully supplied more than 500,000 (approx. 40,000 MVA) transformers which are in active service across India, Bangladesh and Nepal, helping bring light and warmth to millions of families from the remotest corners of the subcontinent to the heights of the Himalayas. Through consistent performance spanning several decades, TAL Transformers have built a strong reputation for quality, ruggedness and reliability with a capacity to withstand the vagaries of T&D networks and minimizing the total cost of ownership for customers. The company is also looking for international collaborations and strategic partners for its new initiatives as part of growth targets over the coming decade. In the words of the MD: For our next stage of growth our attempt is to leverage our past experience, knowledge and credentials, to benchmark ourselves against global leaders, and to build continuous value for our Customers, Employees, Vendors and Shareholders.

PRODUCT & SERVICES OFFERED:TAL offer specialized services to our customers which take advantage of our learning and experiences through 36 years of change in the Indian Power Sector. We understand electricity distribution and transformation technology and offer our expertise to customers having requirements of: 1. Repair of Power Transformers 2. Turnkey execution of Distribution/Transmission Projects

BRANCH OFFICES:Technical Associates Limited has established his branch office at LUCKNOW.

Product Design and Planning:Since all transformers are tailor made, on receipt of the customer order,the manufacturer commence designing the transformer as per customer needs. The drawing is then submitted to the customer for approval. The drawing and bill of material are then issued to various departments to carry out further work as per design.

TRANSFORMER:Principle:A Transformer based on the Principle of mutual induction according to this principle, the amount of magnetic flux linked with a coil changing, an e.m.f is induced in the neighbouring coil.

Construction:A transformer consists of a rectangular shaft iron core made of laminated sheets, well insulated from one another.Two coils p1 & p2 and s1 & s2 are wound on the same core, but are well insulated with each other. Note that the both the coils are insulated from the core, the source of alternating e.m.f is connected to p1p2, the primary coil and a load resistance R is connected to s1 s2, the secondary coil through an open switch S.Thus there can be no current through the sec. coil so long as the switch is open.For an ideal transformer, we assume that the resistance of the primary & secondary winding is negligible. Further, the energy loses due to magnetic the iron core is also negligible.

INTRODUCTION OF TRANSFORMER:A transformer is an electrical device which is used for changing the A.C. voltages. A transformer is most widely used device in both low and high current circuit. As such transformers are built in an amazing strength of sizes. In electronic, measurement and control circuits, transformer size

may be so small that it weight only a few tens of grams where as in high voltage power circuits, it may weight hundred of tones. In a transformer, the electrical energy transfer from one circuit to another circuit takes place without the use of moving parts.A transformer which increases the voltages is called a step-up transformer. A transformer which decreases the A.C.voltages is called a step-down transformer.Transformer is, therefore, an essential piece of apparatus both for high and low current circuits.

THEORY AND WORKING OF TRANSFORMER

When an altering e.m.f. is supplied to the primary coil p1p2,an alternating current starts falling in it. The altering current in the primary produces a changing magnetic flux, which induces altering voltage in the primary as well as in the secondary .In a good-transformer,whole of the magnetic flux linked with primary is also linked with the secondary, then the induced e.m.f. induced in each turn of the secondary is equal to that induced in each turn of the primary.Thus if Ep and Es be the instantaneous values of the emfs induced in the primary and the secondary and Np and Ns are the no. of turns of the primary and secondary coils of the transformer and D / dt = rate of change of flux in each turn off the coil at this instant, we have Ep = -Np d/dt -----------------(1) And Es = -Ns d/dt ----------------- (2) Since the above relations are true at every instant, so by dividing 2 by 1, we get Es / Ep = - Ns / Np ----------------(3) As Ep is the instantaneous value of back e.m.f induced in the primary coil p1, so the instantaneous current in primary coil is due to the difference (E Ep ) in the instantaneous

values of the applied and back e.m.f. further if Rp is the resistance o, p1p2 coil, then the instantaneous current Ip in the primary coil is given by Ip = E Ep / Rp E Ep = Ip Rp When the resistance of the primary is small, Rp Ip can be neglected so therefore E Ep = 0 or Ep = E Thus back e.m.f = input e.m.f Hence equation 3 can be written as Es / Ep = Es / E = output e.m.f / input e.m.f = Ns / Np = K Where K is constant, called turn or transformation ratio. In a step up transformer Es > E so K > 1, hence Ns > Np In a step down transformer Es < E so K < 1, hence Ns < Np If Ip = value of primary current at the same instant t And Is = value of sec. current at this instant, then Input power at the instant t = Ep Ip and Output power at the same instant = Es Is .If there are no losses of power in the transformer, then Input power = output power Or Ep Ip = Es Is Or Es / Ep = Ip / Is = K In a step up transformer As k > 1, so Ip > Is or Is < Ip

i.e. current in sec. is weaker when secondary voltage is higher.Hence, whatever we gain in voltage, we lose in current in the ame ratio. Similarly it can be shown, that in a step down transformer, whatever we lose in voltage, we gain in current in the same ratio. Thus a step up transformer in reality steps down the current & a step down transformer steps up the current. Efficiency:Efficiency of Efficiency of a transformer is defined as the ratio of output power to the input power. i.e. = output power / input power = Es Is / Ep Ip Thus in an ideal transformer, where there is no power losses, = 1. But in actual practice, there are many power losses,therefore the efficiency of transformer is less than one. ENERGY LOSSES:Following are the major sources of energy loss in a transformer: 1. Copper loss is the energy loss in the form of heat in the copper coils of a transformer. This is due to joule heating of conducting wires. 2. Iron loss is the energy loss in the form of heat in the iron core of the transformer. This is due to formation of eddy currents in iron core. It is minimized by taking laminated cores. 3. Leakage of magnetic flux occurs inspite of best insulations.Therefore, rate of change of magnetic

flux linked with each turn of S1S2 is less than the rate of change of magnetic flux linked with each turn of P1P2. 4. Hysteretic loss is the loss of energy due to repeated magnetization and demagnetization of the iron core when A.C. is fed to it. 5. Magneto striation i.e. humming noise of a transformer.

USES OF TRANSFORMER
A transformer is used in almost all a.c. operations In voltage regulator for T.V., refrigerator, computer,air conditioner etc.In the induction furnaces. A step down transformer is used for welding purposes. A step down transformer is used for obtaining large current. A step up transformer is used for the production of X-Rays and NEON advertisement. Transformers are used in voltage regulators and stabilized power supplies. Transformers are used in the transmissions of a.c. over long distances. Small transformers are used in Radio sets, telephones, loud speakers and electric bells etc.

Manufacturing process
a) Core Building CRGO
(Cold Rolled Grain Oriented) steel sheets are used for manufacturing core laminations by the subcontractors. They cut required size of laminations by high accuracy shears. Laminations are stacked instep lap -interleaved fashion to minimize core losses,exciting current and noise level. The yokes and limbs are firmly clamped between steel channels in manner, which reduces vibration,and inherent noise.

CRGO laminated silicon steel

CORE assembly

b)Winding
Annealed/half-hard copper conductors either in the form of a strip or round wires are used in winding operations and dimensions for the winding such as inside diameter and outside diameter are maintained by selecting proper Mandrel. Insulation is provided as mentioned in the design output. The coil tapping leads and phase leads are taken out according to the design output.Coils are kept under clamping pressure and sent for ovening FORMER

Winding conductor

COILS

c) Preparation

of insulating material Pre compressed boards,perma wood (un-impregnated identified laminated wood which can with stand temperatures of upto 1100c); craft paper, crepe paper,etc. are used as insulating material. Components such as cylinders,wedges, spacers, rings etc. are made from these materials by different operations like cutting, edge rounding, chamfering, drilling, machining etc. Insulation paper

d) Core Coil Assembly

The coils are concentrically assembled on the core limbs as per the design details. The core and coil assembly is rigidly supported and clamped. The main leads and tapping leads of coils are then connected to bushings and the tap changers respectively. All these leads are properly clamped and insulated to ensure required electrical clearance and creepage .A tap changer is a selector switch that allows the voltage ratio of the transformer to be changed by increasing or decreasing the turns of the winding. The tapping leads of the coils are connected to the tap changer to allow the additional turns to be brought into or taken out of circuit. In some distribution transformers , the tap changer switch is an off load manual switch ,while in others , the tap changer is an on-load automatic switch.

e)Tank finish and paintings

After welding , tanks are preheated by slot blasting. They are thoroughly cleaned before applying a coat of zinc chromate primer paint on external surface . one coat of weather resisting enamel finish paints is applied . the final coat of external paint is applied , priorto dispatchof ready transformer fitted with accessories and fittings.

f) Ovening
Hot air drying is carried out to remove moisture from the active parts of the transformers . For transformers up to 33kv class drying is carried out in well ventilated ovens for a period till insulation resistance builds up to specific value. For large transformers , above 33kv class, drying takes place in vaccum drying oven . the core - coil assemblyis initially heated for a predetermined period by admitting heated kerosene vapour . And then they are placed under vaccum , this cycle is repeated till all the Moisture is extracted .

g)Tanking
Active part(Core coil assembly) after drying are placed in tank. Bushings of specified rating are mounted on top o side as per design are connected to end terminals . tap changing switch is provided and connected to various tapping leads as per design. The top plate is tightened at specific torque and the filtered oil is filled under vacuum . the tank is tested for leackage by subjecting it to the required pressure after all other accessories are fitted on the tank. The oil is used for further insulating purposes plus the removal of heat from the windings. The assembly of the windings on the core allows gaps to enhance the oil circulation around the

windings . the tank is constructed with fins or tubes to allow better circulation of oil and to provide a greater surface area for contact with the cooling air.

h)Testing
We have state of the art testing facilities including a fully equipped testing room for carrying out of all routine tests such as temperature rise test ,zero phase sequence test etc. every transformer is tested for routine tests specified in standard specification on the completion which a test certificate to this effect is issued All transformers are tested in our sophisticated laboratory for the following routine tests conforming to National and International Specifications on the completion of which a test certificate to this effect is issued. Voltage Ratio, Winding resistance. Impedance Voltage, No load and Load Losses, No load Current Dielectric tests.Factory Pass Collection of Payment After the acceptance of the order from the customer, the company starts the assembling of the transformer according to the technical specification of the customers; after the assembling and testing is completed the finance department issues an invoice and performs3major functions:39CG -Transformer designs are proven for dead short circuits by tests conducted at the independent ,accredited short circuit laboratory of the Government of India.

Finance
Invoice Commercial Invoice Central Excise Duty Customer Payment of Central Excise Duty: The finance department makes sure that the central excise duty on the products is paid tothe competent authorities,only when the duty fees is paid the product is allowed to pass from the factory gate. Commercial Invoice: The finance department also issues a Commercial Invoice a copy of it sent to the branch office and the other copy is sent to the customer. The payment from the customer is received on the basis of the terms of payment and other details mentioned in the invoice.