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UKAS

ISO 9001
ISO 14001

Power
Transformers
The Energising
Solution
Expressions Crompton Greaves promotes a

of Power high level of Research and


Development activities to maintain
a technological lead and
competitive advantage. R & D
operations are structured to
initiate a techno-active response
Crompton Greaves Ltd., right through the company, getting
established in 1937, has witnessed research out of the labs in to the
over six decades of unparalleled products. Numerous awards and
growth to have current sales of ISO 9000 certifications have
over IRs 16 Billion (US $ 330 accredited the exacting standards
Millions). With an electrifying of quality management.

attitude, a fusion of experience Today, Crompton Greaves


and expertise in the field of International Operations are
applied energy, extensive R & D, spread over all the continents in
advanced technology, dedicated the world to become the largest
workforce, superior manufacturing from India in each segment of
skills, exacting standards of Transformers, Switchgear,
quality and diverse and distinctive L.V. Controlgear, Motors and
competencies that converge, Alternators, Pumps and Fans.
Crompton Greaves offers a
As the new millennium consumers
comprehensive portfolio of
plug-in to a switched-on future,
products and services for
Crompton Greaves, a member of
Generation, Transmission,
the B. M. Thapar Group and
Distribution and Utilization of
Invensys plc., will continue to play
power in various applications. Its
an electro-dynamic role
presence is well established and
…engineering the right solutions
widespread, notably in the
… making a difference to life and
Utilities, Industry, Agriculture,
thriving in an increasingly wired
Transportation, Informatics,
world.
Telecommunication and Lifestyle
Products.

Power Systems • Industrial Systems • Consumer Products • Informatics & Telecom


Energising
Solutions
.... for over 60 years!
Crompton Greaves kicked off
the Transformers operation with
their first supply to the US Army
over 60 year’s back! Initial
technology was from Brush
Transformers and Hawker
Siddeley Power Transformers,
both from U.K. and then, from
Westinghouse Electric
Corporation, U.S.A. for
Transformers upto 400 kV to
Mumbai Plant match growing volumes and
changing international
requirements. Having
commissioned over 120 Million
kVA in Transformers, Crompton
Greaves are today the leading
manufacturer of Transformers
and Reactors, with a wide
range, for all critical applications.
To sustain the growing demand
of Transformers, Crompton
Greaves commissioned a new
Gwalior Plant integrated Plant at Gwalior (T2)
spread over 20,000-sq. m. in
1991 and yet another at Bhopal
(T3), spread over 30,000-sq. m.
in 1995. A new Plant for
Amorphous Core Transformers,
having 1,500 kVA capacity was
commissioned in 2001. With
enhanced capacity of 18,500
MVA now, Crompton Greaves
have successfully spearheaded
entry in to the most demanding
Bhopal Plant
markets of the world.

Bhopal Plant - Amorphous Core Transformers Transformer Design Solutions

1
Crompton Greaves have the
capability to produce
transformers from 400 kVA to
900,000 kVA (in a Bank), 3.3 kV 77/96/110 MVA, 11.5/115 kV, GSU Transformer at Rojana & Saha Co-Gen, Thailand
to 500 kV class for various
applications and conforming to
IS, IEC, EN, AS, BS, ANSI and
other international standards.

320 MVA, 16/230 kV, GSU Transformer,


AES Haripur, Bangladesh

POWER TRANSFORMERS
• Generator Transformers for
Thermal, Nuclear, Hydro and
Gas Generating Stations.
• Upto 450 MVA, 500 kV
class, three phase.
• 900 MVA, 500 kV in a bank.
• Auto Transformers for step-up
and step-down
• 500 MVA, 500 kV class,
three phase.
• 900 MVA, 500 kV class in a
bank.
• Reactors, Series and Shunt,
upto 80 MVAr, 500 kV class.
• Multi Winding Auto and
Generator Transformers 180 MVA, 14.7/230kV Transformer

2
SPECIAL FEATURES - OPTIONAL
• Sealed Tank construction to
ANSI standards.
• Noise level of upto 50 dB(A).
• RTCC Panels with PLCs for
SCADA compatibility.
Ž Fibre Optics for direct hot
spot measurement.
• Intelligent on-line monitoring
systems.
• Nitrogen based fire
protection systems.
• Compliance to EU norms.

RTCC Panel

Cast Resin Transformer


DISTRIBUTION
TRANSFORMERS
• Oil Cooled Transformers, 500
kVA to 10,000 kVA, upto 33kV.
Marshalling Box • Dry Transformers upto 2500
kVA. 33kV. (Cast Resin and
Resin Impregnated)
• Amorphous Core
Transformers.
• Unitised Substations.
Unitised Substation

SPECIAL TRANSFORMERS
• Arc and Induction Furnace
Fibre Optic Control Panel
Transformers upto 40 MVA,
33kV, up to 60 kA Current
application.
• Trackside Transformers 31.5
MVA, 25 kV AC, single phase.
• Locomotive Transformers
upto 5400 kVA, 25 kV AC.
• Thyristor Duty Transformers.
• Package Substations upto
2000 kVA.
µp based temperature and voltage Oil Filled Distribution Transformer • Earthing and Auxiliary
control Transformers.
3
TRANSFORMERS, • IDEAS and ANSYS for
TECHNOLOGY structural designs.

Crompton Greaves have • ANSYS for seismic analysis.


absorbed world class • AutoCAD and special add-on
technologies through software for components, parts
collaborations for built in and their quick integration in to
3D View of Transformer components
total reliability. the final Product.
• Brush Transformers, U.K. • Simulation techniques for
noise, vibration, thermal, hot
• Hawker Siddeley Power
spot and seismic analysis.
Transformers, U.K.
• Westinghouse, U.S.A. for Foil
Technology, Distribution and
Power Transformers and
Shunt Reactors upto 500 kV
class.
Tank under simulation test for vacuum • GE, U.S.A. for Amorphous
withstand Core Transformers
• ABB, Sweden for Locomotive
Transformers.
Structural seismic analysis of
Design technology incorporates Transformers
the following state of the art
With deployment of well qualified
techniques and software to
Engineers and Technocrats,
comply with the ever demanding
Crompton Greaves have fully
customer and system
harnessed long experience in
integration needs and the latest
Design and Software, a core
manufacturing techniques .
strength of India, to offer
Layout of Dry Type Transformer • 2D and 3D Finite Element innovative, reliable and efficient
Method (FEM) analysis for Transformer solutions. Advanced
electrostatic and computer systems, design
electromagnetic distribution techniques and simulation of the
• MAGNET for field conditions contribute to fast
electromagnetics. product development and ensure
enhanced reliability – so very
critical for the Transformers.

FEM analysis of core assembly

Clearance Sphere - design verification Transformer Engineering Centre at Mumbai Plant

4
High Speed 'GEORG' CNC Machine

Core assembly of 250MVA Generator Transformer

POWER TRANSFORMERS, The laminations forming the


CORE BUILDING magnetic circuit are assembled
on a special core building
Transformer Cores are built with fixture. The Step-Lap or Mitred
CRGO, low loss silicon steel joints at the core corners
laminations. Use of Hi-B grade ensure a streamlined
and laser scribed laminations magnetic flux path.
for core significantly reduces no
load losses and noise levels as The core limbs are held with
committed. resin bonded glass bands to
eliminate limb bolts. Yokes are
New high speed “GEORG” CNC clamped by solid mild steel
machines for core slitting and plates with yoke studs, ensuring
cropping offers stress free high rigidity for withstanding
laminations without burrs for mechanical shocks during
fully aligned core building. transportation and short
Special dimpled sheets provide circuits. For logistics, five limb
space between laminations for core construction offers reduced
most effective cooling. height for large Power
Transformers.

5
POWER TRANSFORMERS,
WINDING
Electrolytic Grade Copper or
Continuously Transposed
Conductors (CTC) or Epoxy
Bonded CTC are used to the
design requirements. Windings
are made on the vertical or
horizontal winding machines
with great care by well-
experienced techno-craftsmen
in a dust free (5 microns max.)
environment, with positive
pressure for superior
reliability. High quality
pre-compressed insulation, pre
shrunk by a specially designed
process, ensures long service
stability. Thermally upgraded
paper enables emergency
Winding Bay overloading beyond nameplate
rating, wherever desired.
The winding has axial and radial
cooling ducts to ensure effective
heat dissipation in to the oil and
eliminating the hot spots.
For high voltage windings, disc
coils with excellent mechanical
strength are used to take the
stresses due to voltage level. A
special interleaved or shielded
construction offers most uniform
voltage distribution despite
system transients. Finished
coils are compressed by
predetermined clamping force in
a 200 tons, Isostatic Hydraulic
Press, for retaining the
designed geometrical position
of the individual winding.

Vertical Winding Machine

6
POWER TRANSFORMERS,
CORE-COIL ASSEMBLY
The winding is rigidly supported
by a common pressure ring of
densified wood at the top and
bottom, for precise alignment. Micafil VPD Facility
Well profiled angled rings are
placed between HV and LV
windings to reduce voltage
stress levels. The ends and
tapping leads of all the windings
are connected by special extra
flexible, insulated copper
cables, which are rigidly braced
in position. In oil forced units, oil
is circulated inside the winding
by specially designed pipes of Isostatic Press Autoclave
insulated materials.
The core coil assembly is dried
to less than 0.5% moisture
content, by the automated
Vapour Phase Drying (VPD)
plant of MICAFIL. High
mechanical rigidity is achieved
by hydraulic pressing at
calculated force and tightening
all pressure screws. The
core-coil assembly is put into
the tank with proper locating
arrangements. The tank is then
filled with hot oil, filtrated by
High Vacuum Oil Filtration Plant
to max. 5 PPM moisture
content, free of particles above
5 microns size and with very low
gas content, under vacuum to
ensure least exposure to
atmosphere.

Reactor Core-Coil Assembly

7
TEST FACILITIES
In addition to the normal routine
test facilities, the following
major type test facilities are
available in-house for type
testing the Transformers to all
major international standards.
1. Switching and Lightning
Impulse Test System.
2. Partial Discharge and Radio
Interference Measurement
Facilities.
3. Noise Level Measurement
Setup.
4. Temperature Rise Test Plant
5. Dissolved Gas Analyser
(DGA) for oil.
6. Harmonic Measurement and
Analysis
7. Linearity Test Set for HV
Impulse Generator
Reactors
POWER TRANSFORMERS, 8. Vibration Test Plant
QUALITY ASSURANCE The Transformer designs are
proven for dead short circuits by
High standards set for tests conducted at independent,
POWER TRANSFORMERS,
procurement and inputs go a long accredited Short Circuit
TANKS way to ensure reliable Laboratories.
Tanks are built with mild steel Transformers. Quality is ensured
plates to withstand full vacuum, at source for standard materials,
conforming to the International with a qualified and dedicated
standards. The welder’s Supplier base. Continuous
qualification is done as per upgradation of Suppliers and
ASME Section IX. Tanks are close inspection of incoming
designed to roll and skid in materials, controlling
specified directions. in-process parameters and
thorough inspection and testing of
Lugs for jacking, lifting and
the Transformers ensure
hauling are routinely tested for
consistent high-quality standards
dye penetration test. Tanks have
that Customers have come to
welded or bolted top cover. For
expect from Crompton Greaves Dissolved Gas Analyser for oil
large units above 50 MVA, bell
type construction is available.
Tanks are shot blasted
to get a surface finish of SA 2.5,
coated with zinc rich primer and
then painted. Epoxy or
polyurethane painting and spray
galvanising are optionally
offered to specific requirements
for surface finish of the Tank.
The transformer is made ready
for final inspection after
assembly of bushings,
conservator, radiators etc. Test Bench

8
PROCESS CERTIFICATION
All the three manufacturing
Plants are certified to ISO 9000-
2000 and our Mumbai Plant to
ISO 14001 standards as well, by TRANSFORMER PACKING POWER TRANSFORMERS,
BVQI, U.K.. A structured TQM EXPORTS ALL OVER THE
While the main Tank is
programme is in place ensuring WORLD!
transported as per the planned
continuous improvement
design and logistics, the Today over 400 units of
towards world class quality
accessories and tools, first Crompton Greaves Power
standards. The quality
packed in polyethylene, are Transformers up to 320 MVA
assurance systems are backed
shipped in standardised and 345 kV are installed in over
by a strong in-house R & D
seaworthy wooden packing 46 countries around the world.
continuously working to upgrade
boxes, with shipping marks and
and ensure total system reliability. Power Transformer shipping
contents specified for damage
With SAP/R3 implementation, free shipment. calls for a specialised skillset
the internal processes are and meticulous planning
further sharpened to provide TECHNICAL DOCUMENTATION through study of product
effective Transformer solutions, specifications, Port capabilities
all over the world. All the drawings are in and shipping logistics to ensure
AutoCAD, for quick review while safe, reliable, timely and cost
getting approved and thereafter effective passage till installation
TRANSFORMER FINISH
the final drawings can be site in the destination country.
With concealed wiring in rigid submitted on a CD alongwith a Critical aspects of Power
Conduits, Junction Boxes , print copy as required. Transformer logistics and
Elbows etc. to the NEC shipment are planned and taken
The Transformer Installation,
guidelines, a neat wiring layout care of at the design stage itself
Commissioning and
is offered. Great care is taken and the Crompton Greaves
Maintenance Manual is in fully
for using thin, minimum width in-built expertise make a
searchable electronic format
jointless gaskets having minimal significant contribution there.
(PDF) on a CD for easy and
exposure and constrained
quick access to the exhaustive The Result - Crompton Greaves
sealing system, to the
technical instructions. Power Transformers, energising
international practices for
absolutely no leakage of the oil. solutions for over 60 years now!

Painting and finishing

The paint system, epoxy and


acrylic based polyurethane,
would be compatible to the
specified corrosive environment
with good aesthetic finish.
Transformer on trailer

Product improvement is a continuous process. Hence data 9


given in this catalogue is subject to change without
intimation.
Energising
Solutions
.... for over 60 years!

Design Automation Winding Bay

Loading on Ship Isostatic Press

Transformer Exports,
Kanjurmarg (East),
Mumbai (Bombay) - 400 042.(INDIA)
Telephones : +91-22-578 2451
CG International Direct
Fax
: +91-22-579 6902
: +91-22-578 0456
International Operations of Email : vk@cgl.co.in
Crompton Greaves Limited Home Page: http://www.cglonline.com/international/

CG.ID/PTransfo/54/3/02

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