Various types of core stackings are adopted for three phase transformers during ma nufacture.

Some of the core building schemes are shown in Fig. 4.2 which are only representative. Each scheme has its own advantages and disadvantages. The manufacturers should l ook into the applicability of each of these schemes before deciding on the final design of co re building. The scheme and style of assemblies shown in Fig. 4.2 (a) and (b) are exactly the same, except for the configuration of yoke laminations, which are of two pieces in the case of Fi g. 4.2 (a) and of single piece in the case of Fig. 4.2 (b). Two side limbs in both the assemblies are ide ntical, but the shape of centre lamination is different. The number of joints in Fig. 4.2 (a) are eight, whereas they are six in the case of Fig. 4.2 (b). Because of more number of joints, Fig. 4.2 (a) yields mor e losses than Fig. 4.2 (b) for the same core area and flux density. Similarly Fig. 4.2 (c) and (d) and Fig. 4.2 (e) and (f ) are same, except for t he yoke configurations as described above. a C/L C/L C/L C/L HH DD DD b C/L C/L C/L C/L HH DD DD40 POWER TRANSFORMERS : QUALITY ASSURANCE c C/L C/L C/L C/L HH DD DD e C/L C/L C/L C/L HH DD DD f C/L C/L C/L C/L HH DD DD d C/L C/L C/L C/L HH DD DD Fig. 4.2. Types of core stackings for three phase transformers Apart from the models of core building shown in Fig. 4.2, there are some more sc hemes, commonly known as step-lap constructions as indicated in Fig. 4.3 and Fig. 4.4. The construction of step-lap may be cross-step or longitudinal-step . These types of core

building schemes have some specific advantages over other schemes, especially in no-load loss and current. Step-lap core assembly has less no-load loss than conventional stacked assembly. B ut in India step-lap construction is not very popular, since the cost of processing equipments is huge and are beyond the reach of small manufacturing units. The processing equipment is known as Automatic Cut to Length, CNC Control .CRGO SILICON STEEL 41 Cross-step Longitudinal-step Fig. 4.3. Cross-step step-lap construction Fig. 4.4. Longitudinal-step step-l ap construction The national average of T and D losses in India is bout 23 per cent of the gener ated power. Eighty per cent of these losses are attributed to the distribution network. Losses in the d istribution network are mainly due to lengthy feeders, low power factor in the system and transformers. One of the steps for energy conservation, therefore, could be the efforts to reduce transformer losse s. Losses in a transformer consist of no-load loss and load loss. No-load loss (or core-loss) is fixed loss irrespective of loading of the transformer. This loss is more significant, particularly in rural areas where the transformers are lightly loaded for most of the time. It is estimated that about 5 per cent of th e energy consumed in rural areas is wasted due to no-load losses. Therefore, efforts to reduce these losses will be a step towards energy conservation. In India, where the gap between the supply and demand is in creasing day by day, reduction in transformer loss will go a long way in reducing the gap and in incr easing overall efficiency of the distribution network. Amorphous alloy: There has been constant search for transformer core material wi th minimum loss. Iron-Boron-Silicon amorphous alloy has evolved as the low loss m aterial for distribution transformers. Molten metal when cooled to solid state at a very high rapid rate, retain a random atomic structure which is not crystalline. This metal is called amorphous . This resembles glass and is also referred to as glass metal . The need to achieve the required cooling rate restrict s the thickness of the metal to about 0.025 mm, i.e., almost 1/10th of the thickness of the conventiona l CRGO steel. Due to its small thickness and low saturation factor, larger core and consequent ly larger coils and tank size are required as compared to CRGO core transformer. The problem of small thickness is overcome to some extent with the development of amorphous metal strips. This is achieved by compacting a number of thin laminations into comparatively thick ribbons. These strips comm only known as power core , have been developed upto a thickness 0.25 mm. Amorphous strips are four tim es harder than CRGO steel. Hardness along with reduced thickness makes slitting and shearing di

fficult.42 POWER TRANSFORMERS : QUALITY ASSURANCE Due to these and other limitations, the amorphous core technology has been limit ed at present only to distribution transformers in India. Amorphous metal core has some merits . The non-crystal-line structure and random arrangement of atoms give low field magnetisation and high electrical resistivity. Due to low field magnetisation, hysteresis loss is low and due to high electrica l resistivity, eddy currents are suppressed. As such, the core losses in amorphous metal alloys are reduced b y almost 74 per cent as compared to conventional stacked core. The important properties of the amorphous magnetic alloy along with those of the conventional CRGO silicon steel are given in Table 4.1. Table 4.1 Sl. Properties Amorphous alloy CRGO silicon No steel 27 M4 grade 1. Saturation flux density at: 25C 1.55 tesla 2.03 tesla 100C 1.49 tesla 2.09 tesla 2. Core loss 0.21 at 1.4 tesla 1.02 at 1.6 tesla (watts/kg) 3. Excitation power (VA/kg) 0.37 at 1.4 tesla 1.4 at 1.6 tesla 4. Specific resistance 130 45 Ohm-mm 2 /m 5. Hardness DPH 10.3 RB 76 6. Thickness in micron 25 30 275 7. Space factor in per cent 78 82 95 97.5 8. Sensitivity to pressure Appreciable Negligible 9. Magnetostriction Higher Lower 10. Brittleness Higher Lower 11. Available form Ribbons/Foils Sheets/Rolls The most attractive characteristics of amorphous alloy are obviously it s extremely low core loss a reduction of almost 74 per cent and low magnetising current a reduction of almo st 78 per cent. Except these two properties, practically all other properties of amorphous alloy are inferior toCRGO SILICON STEEL 43 those of CRGO steel. It is a challenge to engineers to overcome the inferior pro perties so that the low loss property is exploited in the most cost effective way. The amorphous metal saturates almost at 1.55 tesla whereas CRGO steel saturates at around 2.03 tesla. Hence amorphous metal core transformers require increased core size, larger cond uctor, larger tank and more insulating oil. Thus overall cost of amorphous core transformer i s approximately 40 per cent higher than that of conventional core transformer. Though amorphous core transformer has excellent magnetic properties such as low no-load loss and current, it is not popular in the Indian market because of its high initial cost . Moreover, considering the high rate of failure of distribution transformers, REC has recommended the use o

f suitable protective devices (MCCB with matching characteristics) on LT side of the transformer to pr otect it from faults and shortcircuits which occur frequently on LT lines. With such recommendation, the amorphous core transformers become costlier and remain beyond reach to most of the SEBs. Further, most of the SEBs are not able to undertake repair of failed amorphous t ransformers as they do not have sufficient knowhow as well as infrastructure to handle such rep air work. It is suggested that the SEBs buy a limited quantity of amorphous transformers f or monitoring their performances in the distribution network, as well as to acquaint themselve s in maintenance and repair of such transformers.

Figures 4.15 to 4.26 provided at the end of this chapter may be referred for the construction of amorphous core transformers. Figure 4.5 shows the construction of AMDT core in both closed and open conditions. It is available in the market (on order) duly formed according to the specific size and design of the customer. Figure 4.6 shows the assembly of 4 sets of such AMDT core duly clamped together at the bottom with steel frame. The top laminations are un-bladed and made straight-up. This will facilitate to insert the prefabricated coils around the core limbs. Fig. 4.5. AMDT core Outer CRGO locking tab Core joint AMDT core Finished surfaces Oil vent AMDT core (open) Lamination packs44 POWER TRANSFORMERS : QUALITY ASSURANCE The location of pressboard insulating paper, winding, spacer block, core framing channel, mounting bracket etc. are shown. Open ed core joints Mounting brackets Press board insulation paper Winding spacer blocks Top framing channel Fig. 4.6. AMDT core/coil assembly (core joints open, ready for coil installation ) The next operation is to insert LV/HV coils from the top as shown in Fig. 4.7. T he coils must rest at the bottom support as indicated. The winding leads are shown coming out throu gh the holes of the channel. Opened core joints Mounting brackets Pressboard insulation paper Winding spacer blocks LV/HV winding

connections LV/HV coils Top framing channel Fig. 4.7. AMDT core/coil assembly (core joints open, LV/HV coils installed)CRGO SILICON STEEL 45 Figure 4.8 indicates the re-blading of top laminations to their origin al settings. Pressboard insulations as per design requirements are placed at the top. Closed core joints Pressboard insulation paper Winding spacer blocks LV/HV winding connections LV/HV coils Top framing channel Mounting brackets Fig. 4.8. AMDT core/coil assembly (core joints closed, LV/HV coils installed) The placement of winding spacer blocks and framing channel insulation are shown in Fig. 4.9. Framing channel insulation Winding spacer blocks Mounting brackets Top framing channel LV/HV coils LV/HV winding connections Winding spacer blocks Pressboard insulation paper Fig. 4.9. AMDT core/coil assembly (core/coil assembled final framing)46 POWER TRAN SFORMERS : QUALITY ASSURANCE AMDT core-coil assembly is usually made in up-side down, i.e. inverted condition . Fig. 4.10 shows the arrangement of bottom framing channel with the tie rods in position. Bottom framing channel Tie rods Pressboard channel insulation Mounting brackets Top framing channel LV/HV coils LV/HV windings connections Winding

spacer blocks Pressboard insulation paper Winding spacer blocks Winding spacer blocks Fig. 4.10. AMDT core/coil assembly (final framing fixture)CRGO SILICON STEEL 47 Figure 4.11 shows the clamped core-coil assembly with tie rods holding both bott om and top framing channels. Bottom framing channel Cores Mounting brackets Top framing channel LV/HV coils LV/HV windings connections Winding spacer blocks Tie rods Fig. 4.11. AMDT core/coil assembly (core joint on top) As described above, the usual practice is to assemble the AMDT coil in bottom-up /top-down condition. Now it is the time to invert the assembly, i.e. top-up/bottom-down as indicated in Fig. 4.12. Top framing channel LV/HV windings connections Mounting brackets Cores Tie rods Winding spacer blocks LV/HV coils Bottom framing channel Fig. 4.12. AMDT core/coil final assembly position (core joint on bottom)48 POWER TRANSFORMERS : QUALITY ASSURANCE Figure 4.13 shows all the manufacturing stages right from AMDT core upto the fin al core assembly in sequential order. AMDT core Joint opened Core positions in top frame Core joints opened LV coils installation Core joints closed HV coils installation Final framing assembly Fig. 4.13. 5 Leg-AMDT core and coil assembly