SUMMER TRANING REPORT

ON MANUFACTURING PROCESS OF POWER TRANSFORMER

& PROCESSING OF WINDING COILS

AT

AREVA T&D INDIA LIMITED

NAINI, WORKS, ALLAHABAD

Underkind Guidance Of Mr. R. BASERA (Head of Coil Winding Department) Project Submitted By

ASHWANI KR PATEL
B.Tech. (3rd YEAR) ELECTRICAL & ELECTRONICS ENGINEERING AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD

ACKNOWLEDGEMENT
At the submission of the PROJECT I take the opportunity to express my deep since of gratitude to Mr. R. BASERA (Head of coil winding Department, AREVA T & D, LTD.) is my Project Leader, supporting and guiding me in the smooth period of on month, resulting in successful completion of my project work. I thank him for being with me and guiding me to be on the right back all along. I shall cherish his help and guidance for long time to come. I would also like to extend my special thanks to Mr. CHANDRASHAKHER GOSWAMI (COIL WINDING DEPARTMENT) for helping me in completing my project.

I would like to extend my thanks to R.K. ARORA (ASSEMBLY DEPARTMENT) B.G. SINGH & V.P.SRIVASTAVA (TANKING DEPARTMENT) Last but not the least; I would like to thank the entire management and all company members to whom I interacted during my training for the support coordination.

THANKING YOU ASHWANI KR PATEL

PREFACE
This basic aim of this training is to let the student know the various principles, their application in the life and to become aware of the environment of an industry. Training and such other methods have been used to develop a culture and also the situation, make a strategy to invoke correct principle.

My project is devoted under the heading STUDY OF MANUFACTURING OF POWER TRANSFORMER& PROCESSING OF WINDING COILS at AREVA T&D India Limited, Naini Works, Allahabad with respect to Areva Global Standardization.

ASHWANI KR PATEL

CONTENT

Areva Profile-An Overview. History Of Areva T&D Works At Naini, India... Transformer: An Introduction..... Transformer Manufacturing... Processing of winding coils Conclusion.... Reference..

AREVA PROFILE-an overview

Areva was created in 2001. When it was announced, on 30 November 2000, that CEA-Industry, COGEMA, Framatome ANP and FCI were to merge, a French business daily compared the future structure of the company to a Cistercian abbey that weds perfect symmetry to great dignity. This gave us the idea, as we began the search for a new name, of looking at a list of such edifices to see if one of their names suited our purposes. We wanted a simple name, one that was phonetically pleasant and easy to pronounce, and one that sounded modern as opposed to fashionable, one that stirred the imagination. Our inspiration came from the region of Avila in northern Spain, location of the Arevalo abbey. Its name, minus one syllable, became AREVA. Areva founded in 2005 through the energy & transport of ALSTOM. Areva can trace its origin back to earliest steam power plants and locomotives. Since being found the company has continued to advance expanding both geographically & in the terms of products & services. It has built a reputation as an innovator, through its ability to anticipate consumer need not only with the technology nut also through its service and finding solution. With its registered office in PARIS, today is one of the leading suppliers of component system and services to the power generation, transmission and distribution, rail transport and marine infrastructure market and company. Areva has turnover of 15 billion U.S. $ and employs over 1, 10,000 people in over 60 countries. It has preface in INDIA in all its chosen area of business and operation, through three main companies one of which is AREVA Ltd. In India AREVA has turnover of Rs. 1, 10,000 crores and about 6200 people.

Areva Ltd. Is committed to quality and service it has therefore adopted formal quality management system helping it to demonstrate its continual ability to do so

the ultimate satisfaction of customer service. Areva Ltd is a well known company internationally; basically there are three divisions in this organization. Power transformer Distribution transformer PSS(Package Sub Station) Areva has turn over of 15 billion US dollars and employees over 1, 10,000 people in over 60 countries. It has presence in India in all its chosen area of business & operates, through three main companies, one of which is AREVA Ltd. In India, AREVA has turn over of Rs. 1100 crore & about 6200 people

HISTORY OF AREVA T&d works AT NAINI, INDIA

History of AREVA at Naini is not so long. As AREVA has taken over Naini T&D division from ALSTOM in 27 September 2005 as well as the following division of India: Kolkata. Chennai.

AREVA T&D NAINI WORKS

The Naini site is one of AREVA T&Ds successful and highly developed power transformer production plants. Globally, we have factories and technical centers dedicated to power transformers in nine countries spread across four continents. Incorporated in 1957, the Naini transformer factory has more than 50 years of excellent operating experience in manufacturing power and distribution transformers. Before 23rd September 2005 it was known as ALSTOM Limited. It is located 12 km from Allahabad in the state of Uttar Pradesh (about 600kms from New Delhi & 800kms from Kolkata). The unit is spread over a total are of 87276 meter square providing employment to nearly 700 people. The unit has the certification of IMS. The unit is engaged in the production of power transformers,

distribution transformers and MV product lines. It is the only unit in India producing the oil base transformers. The Naini factory pioneered in the manufacture of shell type furnace transformers in India and holds Numero Uno position in arc furnace duty transformers. AREVA Naini has supplied the largest number of transformers in this category to its customers all over the country.

Range of Products at Naini Works

The product range includes power transformers of all types upto 400kv class series and distribution transformer : Distribution and Power Transformers up to 400kv class. Dry type Mining Transformers. Single phase track side transformers for railways. Rectifier transformers. Shunt reactors of coreless and gapped core types. Current limiting series reactors. Sealed type air/glass cushioned transformers. Air furnace transformers. Furnace transformers for calcium carbide, Ferro silicon, Ferro manganese, Ferro chrome. Dry cool breathers. On load tap changers. Radiators suitable for transformers. Auto booster transformers. Compact substations. At present Naini Works has the capacity to manufacture 6000 MVA Power Transformer annually.

Range of Products at Naini Works

Transformer: - An introduction
PRINCIPLE

A transformer is a device that transfers electrical energy from one circuit to another by electromagnetic induction (transformer action). The electrical energy is always transferred without a change in frequency, but involves changes in magnitudes of voltage and current. A transformer consists of two coils called windings, which are wrapped around a core. The transformer operates when a source of ac voltage is connected to one of the windings and a load device is connected to the other. The winding that is connected to the source is called the primary winding. The winding that is connected to the load is called the secondary winding.

Equivalent circuit

APPLICATIONS Transformers are used extensively in AC power systems because they make possible power generation at the most desirable and economical level (10-20 kV), power transmission at an economical transmission voltage (as high as 400-1000

kV) and power utilization at most convenient distribution voltages (230/400 V) for industrial commercial and domestic purposes.

TYPES OF TRANSFORMERS
The transformers are mainly of two types: (A) (B) On the basis of construction. On the basis of range of rating & purpose in power system.

(A) On the basis of construction: # Core Type:

The magnetic core is built of laminations to form a rectangular frame and the windings are arranged concentrically which are bounded around other links of the core. Each limb carries one of the primary & secondary windings so that the two windings can be closely coupled together to keep the leakage low.

# Shell Type:
In this type, windings are put around the central limb and the flux path is completed through two-side limb. The central limb carries total mutual fluxes while the side limbs forming a part of a parallel magnetic circuit carrying of the total flux. Consequently, the cross sectional area of the central limb is twice that of each of the side limbs.

(B) On the basis of Range of Rating & purpose in Power System: # Power Transformer (PT):
This is installed at the generating end of the transmission line. PT is used in electrical power transmission system. They step up the voltages at the power

stations at the suitable level so that they can be transmitted efficiently. This class of transformer has the highest power ratings & the highest continuous voltage ratings.

# Distribution Transformer (DT):

This is installed at the receiving end of the transmission line. These transformers provide transformation from 11 KV and lower voltages down to the level of final distribution level. These are smaller and lighter and do not require specialized handling and lifting equipment of large power transformers. They do not require very high vacuum carbide tool for cutting CRGO.

Transformer(Comprises) Primary winding. Secondary winding. Core: air, ferrite and iron. Air-core and ferrite-core transformers. High-frequency applications. Iron-core transformers.

Transformer manufacturing
The main elements of a transformer are:-

Diagram showing the parts of a transformer

Following is the procedure through which the transformers are built. 1. Core Cutting: The Cold Rolled Grain Oriented (CRGO) laminations are cut by microprocessor controlled slitting and cropping line with a very high dimensional accuracy. The carbide tipped tool used for cutting prevents blur at the edges. 2. Core Building:

Core laminations are assembled carefully on a made core-building platform and the build-up core is erected along with the platform to avoid mechanical stress on the core. Resin impregnated fiberglass tapes instead of conventional yoke bolts to avoid local hotpots and bolt insulation failures clamp both legs and yokes. 3. Coil Winding and Assembly: The winding shop is equipped with vertical and horizontal winding machines capable of producing all types of windings for distribution transformers. Spiral, Crossover, Helical windings, Continuous Disc and Interleaved/Interceded winding with multiple strands of copper conductors are usually adopted for distribution transformers. The coils after pre-assembly on a dummy core are then lowered on the core legs and after top yoke filling the coils are clamped by pressure bolts. Connections from winding to various terminal bushing and tap changer are made by paper insulated flexible cables and a sophisticated fully automatic crimping machine produces currents joints.

4. Drying And Impregnation: Greater care is taken when drying individual coils and insulation components to ensure that they match duly cycle and short circuit forces, which the winding encounter in services. Core and coil assembly is dried through a very efficient vacuum drying autoclave, which ensures the extraction of moisture to zero level. After the drying process every winding, clamping and cable connection is checked and coil is lowered into the tank. Filtered and degassed oil then filled into the tank under the vacuum filter plant until the required insulation level is achieved.

4. Final Assembly: During final assembly all pipe works, bushings and radiators and fitted to the transformer. 5. Testing: The testing plant is fully equipped to test the transformers up to 132KV to ensure that they meet the customer specifications and conforms to the relevant national and international standards

FLOWCHART OF MANUFACTURING PROCESS

Import of CRGO material Slittng and Mitring Core building without top yoke

Procure copper rod

Convertion to insulated conductor

Coil winding
Core errction with platform Final service of core building

Dummy coil assembly

Vacuum dryout

Oil impregnatiov under vacuum

Final service of core winding

Mounting of accessories

Final oil filling

Final oil circulation setting

Core-Coil assembly

Top yoke building clamping

Mounting of tap changer

Lead connection

Primary electrical test

Trail tanking

Electical test

Dismantling & preparation for despatch

Packing forward

CORE CUTTING

Cores are cut in various shapes to form complete unit or window of a transformer. Inside the AREVA two ways are adopted: 1. Cutting along the slitting line through SLITTER, during the cutting 0.5 mm from both sides are cut out to make edges. 2. MITER CUTTING : Here the core material is cut into various shapes through the software having computerized controls. Various shapes are:

Note : the core material is of core rolled grain oriented steel

STORED CRGOS

SLITTER

MITER CUT

VAROUS SHAPES

BUNDLED ASSEMBLY

DEPARTMENT 2

COIL WINDING:

1. Transformer winding are made up of solid stranded copper or aluminum strip conductors. 2. Conductors are insulated with cellulose material (cloth, paper) known as minor insulation (also winding layers are insulated from each other). 3. Major insulation, insulating cylinders made of specially selected pressed board or synthetic resin bounded cylinders is used b/w lv & hv, lv & core. 4. Types of Coil winding adopted

Standard or Non standard winding

DISC TYPE

HELICAL TYPE

For high voltage winding

for low voltage winding

Also tapped for voltage control

FITTING:

 CORE sheets are placed one onto another to form bundles, thus it forms one complete leg of power transformer window (number of sheets to be bundled is calculated as per design and ratings). Adhesive are used to fix the core and are pressed through CLAMPS and BELTS.

ASSEMBLY
The coils are lowered onto the legs of the window as shown:

YOKE

LEGS COIL

WOUNDED

After this various connections are made, OLTC is also connected with the TAPPING made on the windings& hv & lv terminals are stretch out for the main bushing.

TANKING

Tanking is a procedure of embracement of complete unit (active unit) in a mild steel tank, the unit being enclosed includes (core entrapped with windings).
Assembly + Green card

Tank preparation

Auto clave (VPD process)

Servicing

Pressure test

Internal testing

Physical inspection

Dismantling & dispatch

The standards for tanking are completely regulated with customers demand for e.g. transformer once sent to Iceland demanded percentage of steel into the tank to be high.

DRYING AND IMPREGNATING OIL IMMESED POWER (AUTO CLAVE PROCESS)

TRANSFORMERRS AND REACTORS # GENERAL This Specification covers the drying and oil impregnation of all Transformers and reactors having cellulose insulation using Vapour Phase Drying (VPD) or conventionally heated vacuum oven (AUTOCIAVE). The sequence of drying and impregnation is designed to process the Transformers in a minimum of time and minimum exposure to atmosphere. A log sheet must be maintained for each stage for each transformer. The dry out records shall be verified and the acceptance of all parameters shall be endorsed by the process in charge # TYPE OF PROCESSES Five processes are enumerated, dependent on voltage class and rating of transformer and whether vapour phase dry out method is adopted or conventional heating and vacuum dry out method is adopted. Without specific instructions from the Technical Manager or Quality Manager no unit should be dried out or impregnated to a process poorer than the voltage class to which it is applicable. However, Designers may specify by a separate Technical Instruction, a better class of processing should this be necessary. Oily units shall be processed by the Vapour Phase method according to the voltage class. Vapour Phase method of dry out is preferred to conventional heating and vacuum drying method and hence, Process -5 shall be resorted to only in case of exigencies. # TRIAL TANKING PRIOR TO DRYOUT: The core and winding assembly of 1st unit shall be placed in the clean transformer tank, if tank is available to ensure that a good fit and the electrical clearances are correct to drawing dimensions. It is essential that all internals connections are cut to length and terminations made to ensure correct disposition of leads. All

insulation e.g. core seating insulation window wedges. CT washers etc. shall be ready. Additional winding spacers and top clamping blocks must also be available to facilitate procedures at the final clamping and servicing stage. # TRANSFORMER OIL On delivery to the factory, all transformer oil shall be sampled to confirm that it meets the requirements of the Purchasing specifications and that the following are conditions met: Water content < 10 ppm

Electric Strength > 50 kV measured on 2.5 mm IEC gap. Resistivity Visible Fibers > 13 * 1012 ohm m at 30*C <3

SOAKING TIME:

400 kV class 245 kV class 145 kV class Below 145 kV class

24 hrs 12hrs 8 hrs. 6 hrs.

HOT OIL CIRCULATION: OIL CIRCULATION AND FILTER TREATMENT. All transformers shall have oil filtration and degassing treatment after impregnation. Oil shall be circulated through a processing plant for sufficient time to pass the total volume of oil at least 3 times for below 220 kV and 5 times for 220 kV and above (if non-ODAF). For ODAF transformer, maintain parallel oil circulation by running jobs own pump (1 pump). Units requiring heat run tests before the HV tests shall have oil treatment after heat runs also.

 OIL SAMPLES Oil samples shall be taken towards the end of the filtration period, From the bottom sampling valve and tested to the limits specified in Table 2 (C). If the sample fails to meet these limits further treatment shall be considered. The final decision shall be made by the QUALITY MANAGER.

ERECTION 1. After servicing the final dry out phase is carried out with simultaneously filling of oil, following to this phase comes erection. 2. In short it is an assembling phase where all the like gasket, turrets(hv & lv), bushing, CTs etc are fitted on the tanked job.

Erection is followed by commissioning Where a quality controller checks for the Standards and quality Quality check of all accessories that have to be fitted

For example: Capacitance check of OIL Impregnated Paper bushing according to rated Value as mentioned. IMPORTANT: 1. Here while erection all sharp edges has to be removed 2. All burrs are to be removed.

 DISPATCH PHASE After testing is completed and before dispatch from the factory all necessary work, e.g. removal of bushings etc. shall be performed. Precautions with regard to exposure and oil levels enumerated elsewhere in this specification shall be observed during this work. A final vacuum of 5 torr. Or better shall be drawn on the tank for 4 hours before topping up with oil to shipping level in case of oil filled shipment of transformer. A shipping list is made concerning the General arrangement drawing which list out the external attachments of a power transformer to be send to customers .The shipping list carries job number, indent number, contact number of customers, rating of transformer as shown below: Thus we have the phases as under: Shipping list Commissioning Physical inspection of tank before placing it Onto trailor Final inspection for traveling point of view

TESTS Test shall be carried out to evaluate the performance of the material and appliances generally as per provision of IS:2026 where customer inspection is specified, not less than 15 days notice shall be given to the customer in order that he may be represented. Tests are not required to be performed on bought out equipment like oil coolers, oil actuated relays, etc.

Following tests are performed on transformer:Type Tests- The following shall constitute the type tests: 1. Measurement of winding resistance. 2. Measurement of voltage ratio and check of voltage vector relationship. 3. Measurement of impedance voltage/short-circuit impedance (principal tapping) and load loss. 4. Measurement of no-load loss and current. 5. Measurement of insulation resistance. 6. Dielectric tests. 7. Temperature rise and tests on on-load-tap-changers, where appropriate. Routine tests- The following shall constitute the routine tests: 1. Measurement of winding resistance. 2. Measurement of voltage ratio and check of voltage vector relationship. 3. Measurement of impedance voltage/short-circuit impedance (principal tapping) and load loss. 4. Measurement of no-load loss and current. 5. Measurement of insulation resistance. 6. Dielectric tests. 7. Temperature rise and tests on on-load-tap-changers, where appropriate. Special tests- The following tests shall be carried out by mutual agreement between the purchaser and the supplier; 1. 2. 3. 4. 5. 6. Dielectric tests. Measurement of zero-sequence impedance of three phase transformers. Short-circuit tests. Measurement of acquits noise level. Measurement of the harmonics of the no-load current. Measurement of the power taken by the fans and oil pumps.

Other tests are carried out on transformer are:1. 2. 3. 4. 5. 6. 7. Insulation TestClearance/Flash TestImpedance Voltage TestNo-Load Loss TestLoad Loss TestImpulse TestPartial Discharge Test-

Conclusion
Through this Project i have gained a lot of theoretical as well as practical knowledge about transformers. It has given me an insight into the design, construction and testing of transformers. However, it was not possible to get deep knowledge and understanding of each and every aspect of the manufacturing process of a transformer, it being a very extensive process. Nevertheless, I tried my best to get an overview of each stage from design to construction to transport of transformer.

This project has given me an experience to think deeply, organize my thoughts and analyze practical problems.

References

1. AREVA T&D profile from http://www.areva-td.com 2. AREVA T&D,Naini works profile from http://www.areva-td.com 3. Article on transformer and their types from http://www.wikipedia.org 4. ABB Special Transformers pdf from http://www.abb05.com 5. Article on Special Transformers from The J&P Transformer book. 6. A2-305 _ 2008. pdf of Design and testing of 300 MVar Shunt

Reactors from http : //www.cigre.org