Transformer

Training material series

E01

Transformer

Transformer
The large power transformers used in generating

stations, transmissions at high voltage and at

receiving stations are generally of large capacity
such as 100 MVA to 1000 MVA ratings.
These are generally oil immersed and three
phase construction up to 315 MVA rating.
For further higher MVA 3 numbers of single
phase transformers are installed to form a bank
of three phase system.
The oil immersed transformers are generally
preferred due to their capability of delivering
higher power by using effective cooling methods

Major components of a power

transformer
1. Tank: Fabricated from MS sheets with adequate

stiffening
2. Winding: Paper insulated copper conductor
3. Core: Assembled from thin low loss magnetic
steel sheet
4. Oil:
Mineral insulating oil of high electrical
strength
In addition there are many fittings and accessories,
controlling and safety devices associated with the
large power transformers

Critical Check Points for

Transformer Tank
1. Tank
1.1. Air leakage test At
normal pressure
due to oil head plus 35
Kpa and permanent
deflections
are
recorded.
The permissible values
varies upon size of
plate
between
stiffeners (refer to
CBIP
norms).
This
ensures robustness of
enclosure
during

Transformer Tank
1.2.Vacuum withstand test.
At an internal pressure of 25 torr for

one hour, the permanent deflection

is measured on flat plates.
For the permissible values refer to
CBIP (Central board of irrigation and
power.) norms. This ensures that the
internal electrical clearances with
respect to the tank wall or cover to
live parts are in safe limits.

1.3. D P test (Dye penetrated test).

Dye penetration test is conducted
on load bearing welds of lifting lugs,
jacking pads,.
This
ensures
that
completely
assembled and oil filled transformer
can be lifted safely on four hydraulic
jacks during erection at site.

Transformer winding
2.0. Winding
2.1. Generally bare copper
conductor or enameled
copper conductor in
rectangular section with
multi layer Kraft insulating
paper covering is used.
The dimensional
verification of conductor
size, enamel coating
thickness, paper covering
thickness and the method
of paper wrapping is
checked according to
drawing and specification.

Transformer winding
2.2.
In
large
power
transformers the windings are
subjected to high voltage
stresses.

The

withstand
capacity
of
insulation covering is largely
dependent
on
the
smooth
rounding of the corners and burr
free conductor.

Hence the visual check is done on

a sample of bare conductor piece.

The cross section is magnified to

30 times on profile projector and
compared to the contour of the
conductor with the specified
contour traced on the transparent
film.

3.0 Core
3.1. Various grades of
low loss magnetic steels
sheets are available.
The designer specifies
the specific grade of
steel for a particular
design
depending
upon the overall cost
and agreed losses in
that rating of the
transformer.
The verification of the
grade of steel is done
in the laboratory.

CORE
3.2. After various

operations of
slitting, cropping,
piercing, deburring, and
assembly of core
according to
drawing, it is
clamped with
clamp plates and
yoke through yoke
bolts.

Transformer core

The clamp plates and yoke bolts are

insulated to eliminate closed magnetic

conducting path.

This ensures that magnetic core steel

punchings are not shorted and closed
magnetic path is not available for
stray flux.
3.3. The isolation of core to clamp, core
to yoke bolts, and core clamps to yoke
bolts is ensured at the stage of core
building, after coil assembly, after
pressing of coils in dried and hot
condition and after final assembly and
testing of the transformer.
The test performed is called isolation
test at 2 KV to 10 KV for one minute
withstand.

4.0

Transformer oil

The
function
of
transformer oil is many
fold
4.1. Good insulating media
in a highly voltage stress
surrounding,
4.2.
Improve
dielectric
characteristics of cellulose
paper after impregnation
into the pores of paper.
4.3. To carry heat from
active parts like winding,
core,
insulation
to
dissipating surfaces like
tank wall, radiators or

Transformer oil
4.4.
It
quenches
arc
developed in diverter or
selector switch of the tap
changer or due to minor fault
in the windings
4.5. It also protects the
cellulose
insulation
from
absorption of moisture and
there by maintaining its life
span.
4.6. To ensure the desired
properties of the transformer
oil
following
tests
are
performed
during
manufacturing stage
4.6.1. Electrical strength 70
KV minimum

Transformer oil
4.6.3. Tan delta at 90
degree C = 0.01 max
4.6.4. Resistivity at 90
degree C= 6X 10 ^12 ohm
cm minimum
4.6.5 Water content ppm
= 10 max
Vacuum
drying
process,
final
tests
such as routine tests,
type tests and special
tests shall be covered
in next session