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BHARAT HEAVY ELECTRICALS LIMITED: IT’S OVERVIEW BHEL is the largest engineering and manufacturing enterprise in India

BHEL is the largest engineering and manufacturing enterprise in India in the energy / infrastructure sector today. BHEL was established more than 40 years ago when its first plant was set up in Bhopal in 1956, which signaled the dawn of the heavy electrical industry in India. Today, it is the largest engineering and manufacturing enterprise of its kind, with a well recognized track record of performance, making profit continuously since 1971-72 and paying dividends since 1976-77. BHEL caters to core sectors of the sectors of the Indian Economy viz. Power Generation, transmission & distribution, Industries, Transportation, Telecommunication, Renewable Energy and Defense etc. The wide network of BHEL’s 14 manufacturing division, four Power sector regional centers, a large number of project sites, eight service centers and 15 regional offices, enables the company to promptly serve its customers and provide them with suitable products, system and service efficiency and at competitive prices. The quality and reliability of its products is due to the emphasis on design, engineering, and manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world, together with technologies developed in its own R & D centers. BHEL has acquired certifications to Quality Management Systems-ISO 9001, Environmental Management Systems-ISO 14001 and Occupational Health and Safety Management Systems-OHSAS 18001 and has also adopted the concepts of Total Quality Management and Environmental Management.




“A world class innovative, competitive and profitable engineering enterprise providing total business solution”. A world class engineering enterprise committed to enhancing stakeholder value.


To be an Indian Multinational Engineering Enterprise providing total business solution through quality products, system and services in the fields of energy, industry, transportation, infrastructure and other potential areas.


Zeal to Excel and Zest for change.

Integrity and Fairness in all matters.

Respect of Dignity and potential of individuals.

Strict adherence to commitments.

Ensure speed of response.

Foster learning creativity and teamwork.

Loyalty and pride in the company.


A dynamic organization is one which keeps it’s aim high, adopts itself quickly to changing environment. So here we are in BHEL.


To maintain a leading position as a supplier of quality equipment, system and services in the field of conversion, transmission, utilization and conservation of energy for applications in the areas of electric power, transportation, oil and gas exploration industries. Utilized company is capabilities and resources to expand business into allied areas and other priority sectors of the economy like defense, communications and electronics.


To ensure a steady growth by enhancing the competitive edge of BHEL in existing new business areas and international market so as to fulfill national expectation from BHEL.


To provide an adequate return on capital employed, primarily through improvements in operational, efficiency, capital utilization, productivity and adequate internal resources to finance the company’s growth.



To enable each employ to achieve his potential, improve his capabilities, perceive his role and responsibilities and participate and contribute to the growth and success of the company.


To achieve technological excellence in operations by developments of indigenous technologies and efficient absorption and adoption of imparted technologies to suit business and priorities and provide competitive advantage to the company.


To fill the expectation which state holders like government as owner, employees, customers and the country at large have from BHEL.


Power Generation sector comprises thermal, gas hydro and nuclear power plant business. BHEL supplies sets account for nearly 65% of the total installed capacity in the country.


BHEL offers wide-ranging products and systems for T&D applications. Products manufactured includes power transformers, Instrument Transformers, Dry type transformers, Series and Shunt Reactors, Capacitor banks, Vacuum & SF6 circuit breakers, Gas-insulated switchgears and insulators.


BHEL is a major contributor of equipment and systems to industries, cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process industries. The range of system and equipment supplied includes capacitive power plants, co-generation plants, industrial steam turbines, industrial boilers, gas turbines, heat exchangers and valves, seamless steel tubes, electrostatic preceptors, fabric filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process controls.


BHEL is involved in the development, design, engineering, marketing, production, installation and maintenance and after sales service of rolling stock and traction propulsions systems. BHEL manufactures electric locomotive up to 5000 HP, diesel electric locomotives from 350 HP to 3100 HP, for both main line and shunting duty applications. It also produces rolling stock for applications viz. overhead equipment cars, special well wagons and Rail-cum road vehicle.


BHEL also caters to Telecommunication Sector by way of small, medium and large switching systems.



Technologies that can be offered by BHEL for explaining non-conventional and renewable sources of energy include: wind electric generators, solar photovoltaic systems, solar heating systems, solar lanterns and battery-powered road vehicles.


BHEL’s products range includes Deep Drilling Oil Rigs, Mobile Rigs, Work Over Rigs, Well Heads and X-Mas trees, choke and Kill Manifolds, full Bore Gate valves, Mud line Suspension system, Casting support system, Sub-Sea well heads, Block valves, seamless pipes, Motors, Compressor, Heat exchangers etc.


BHEL is one of the largest exporters of engineering products & services from among the major power plant equipment suppliers in the world.

India, ranking


First Generation Units


(Heavy Electrical Plant)


(Heavy Electrical Equipment Plant)


(Heavy Electrical Power Equipment Plant)


(High Pressure Boiler Plant)

Second Generation Units


(Transformer and Locomotive Plant)


(Central Foundry and Forge Plant)


(Seamless Steel Tube Plant)

Unit through Acquisition and Merger


(Electronic Porcelain Division)

New Manufacturing Units


(Boiler Auxiliaries Plant)


(Insulator Plant)


(Component and Fabrication Plant)


(Industrial System Group)

Repair Shop


BOMBAY (Motor Repair Shop)

VARANASI (Heavy Repair Shop)

BHEL is growing concern to meet the changing needs of the nation has taken it beyond power into the total gamut of energy, industry and transportation. BHEL is also to offer a service in each of this field. Its manufacturing capability is supported by a corporate R&D division at Hyderabad which works closely with the research and development cells at various units and Welding Research Institute at Tiruchirapalli.



Thermal sets and Auxiliaries.

Steam generators and Auxiliaries.

Industrial fans.

Electrostatic precipitators.

Air pre heaters.

Nuclear power equipments.

Hydro sets and Auxiliaries.





Heat Exchangers.


Porcelain/Ceramics insulators.

Seamless steel tubes.

Casting and forging.


Turnkey power station.

Data acquisition Systems.

Power systems.

HVDC Commissioning systems.

Modernization and Rehabilitation.



Diesel Electric generators.

AC/DC locomotives.

DC locomotives and loco shunters.

Traction system for railways.

Electric trolley buses.




T.G. sets.

Power devices.

Solar Cells.

Photo Voltaic cells.

Gas Turbines.


Drive Turbines.

Oil rigs.

Blow out preventers.

Wind mills.

Control systems for electric devices.










By the end of the fifth year plan, it was envisaged by the planning commission that the demand for the power transformer would raise in the coming years. Anticipating the country’s requirement, in 1974, BHEL started a new plant in Jhansi which would manufacture power and other type of transformer in addition to the capacity available at BHEL in Bhopal. The Bhopal plant was engaged in the manufacture transformers of large rating and Jhansi unit would concentrate on power transformers, instrument transformers, traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the N.H. No 26 on Jhansi Lalitpur road. It is called second-generation plant of BHEL set up in 1974 at an estimated cost of Rs 16.22 crores inclusive of Rs 2.1 crores for township. Its foundation was laid by late Mrs. Indira Gandhi the prime minister on 9 th Jan. 1974. The commercial production of the unit began in 1976-77 with an output of Rs 53 lacs since then there has been no looking back for BHEL Jhansi

The plant of BHEL is equipped with most modern manufacturing processing and testing facilities for the manufacture of power, special transformer and instrument transformer, Diesel shunting locomotives and AC/DC locomotives. The layout of the plant is well streamlined to enable smooth material flow from the raw material stages to the finished goods. All the feeder bays have been laid perpendicular to the main assembly bay and in each feeder bay raw material smoothly gets converted to sub assemblies, which after inspection are sent to main assembly bay.

The raw material that are produced for manufacture are used only after thorough material testing in the testing lab and with strict quality checks at various stages of productions. This unit of BHEL is basically engaged in the production and manufacturing of various types of transformers and capacities with the growing competition in the transformer section, in 1985- 86 it under took the re-powering of DESL, but it took the complete year for the manufacturing to begin. In 1987-88, BHEL has progressed a step further in under taking the production of AC locomotives, and subsequently it manufacturing AC/DC locomotives also.
































BPRV - Discontinued


BHEL, as an integral part of business performance and in its endeavor to becoming a world class organization and sharing the growth global concern on issues related to Environment, Occupational Health and Safety, is committed to protecting Environment in and around its own establishment, and providing safe and healthy working environment to all its employees. For fulfilling these obligations, Corporate Policies have been formulated as:


Compliance with applicable Environmental Legislation/Regulation;

Continual Improvement in Environment Management Systems to protect our natural environment and control pollution;

Promotion of activities for conservation of resources by Environmental Management.











Compliance with applicable Legislation and Regulations.

Setting objectives and targets to eliminate/control/minimize risks due to Occupational and Safety Hazards.

Appropriate structured training of employees on Occupational Health and Safety (OH&S) aspects.











Periodic review of OH&S Management System to ensure its continuing suitability, adequacy and effectiveness;

Communication of OH&S Policy to all employees and interested parties.






Main aim behind the rotation of various departments is that one can understand the working of each and every department and to see that how people (workers, middle level executives, top officials) work in corporate environment. Main departments of BHEL Jhansi are





There are separate stores for different type of material in the BHEL There are three sections in store;

Control Receiving Section

Custody Section

Scrap Disposal Section

Functions - A list of material coming in store is prepared and Quality Control people are called for inspection. If material is found as per standard SRV (Store Receipt Voucher) is issued for each material. A total of 08 SRV’s are prepared. Some materials like Silicon oil, Transformer oil, insulating material etc. are directly stored in the Bays. Scraps are also sold through unit by a MATERIAL SCRAP TRADING DELHI.


Fabrication is nothing but production. This shop deals with the manufacturing of transformer and locomotive components such as tanks, plates and nuts & bolts. It comprises of three bays i.e. Bay 0, Bay 1 and Bay 2.


This is the preparation shop where according to the required drawings, the cutting of different components of different materials is done. This section has the following machines:

Planer machine It is used to reduce thickness.

Cutting machine

CNC/ANC Flame cutting machine To cut complicated shaft using Oxy- Acetylene flame.

Pantograph flame cutting machine.

PUG cutting

Shearing machine- This machine is used for metal sheet. Cutting range is 2mm to 6mm. Suitable materials for use are Al, Standard steel and Cu.


Bending machine- It is hydraulically operated. Pressure gauge is used to the pressure applied. Stopping mechanism is used by screw to prevent the collapsing the ram blade with bending grooves (Die).

Rolling machine- It is used to reduce the roll thickness. The roller material used is High Carbon Steel.

Flattening machine-It is used to straighten the job.

Radial Drilling machine- In this machine, tool can move radically. In this cutting oil mixed with water is used to cool the drill tool is used as the material to be drilled. Different drill tools are used from 2mm to 100mm dia.

Nibbling machine- Used for straight cutting, circle cutting, nibbling, circular and square punching.

Plano milling machine

Plasma cutting machine- Used for non-ferrous metals.

Hydraulic guillotine shear- used to cut the sheet which has maximum cross-sectional area (3200*13 sq. mm).

Pacific hydraulic shear &pressure- hydraulically operated machine to cut the sheet of different thickness.

Hydraulic power press- has the capacity of 100 tones and used for flattening the objects.

Butler machine- for facing, taping and shot cutting.


It is an assembly shop where different parts of tank come from bay 0. Here welding processes are used for assembly, after which a rough surface is obtained which is eliminated by Grinder operating at 1200 rpm.


It is also assembly shop dealing with making different object mentioned below:

Tank assembly

Tank cover assembly

End frame assembly.

Foot assembly.

Cross feed assembly.

Core clamp assembly.

Pin and pad assembly.

The various process of assembly are fitting, welding and testing. Fitting- In this section,different components are fit according to the drawing requirements. Welding- In this section , welding of the different components of different drawings by permanent joints is done.

Testing- When the tank for transformers is completed, then we check the leakage tests on the tanks. There are two types of leakage tests, which we have to perform on the transformer.


AT(Air leakage test)- In this, tank is filled by compress compressed air and dip the tank in the shop solution for bubble test.

VT(Deflection test)

Shot blasting-It is firing of small materials with the high pressure of 7 kg i.e. acid picking. It is done on different parts of jobs for removing carbon layer from its surface before painting.

Painting- After shot blasting, the tank is painted for corrosion resistant.

After assembly some tests known as NON DESTRUCTIVE TESTS are carried out. They are:

Ultrasonic Tests: To detect the welding fault on the CRO at the fault place high amplitude waves are obtained.

Die Penetration Tests: Red solution is put at the welding & then cleaned. After some time white solution is put. Appearance of a red spot indicates a fault at the welding.

Magnetic Crack Detection: Magnetic field is created & then iron powder is put at the welding. Sticking of the iron powder in the welding indicated as a fault.

X-Ray Test-It is same as human testing and fault is seen in X-ray film.


It is split in two parts, half consists of machine shop and the other half consists of winding of dry type transformer.

Here are basically three sections:

Machine Section.

Copper Section.

Tooling Section.


The operations to form small components of Power & Traction Transformers are done in section. The shop consists of following machines:

Lathe machine

Central lathe machine- It consist one tailstock, headstock low part of tailstock is fixed & tailstock spindle is moving. On this machine facing, turning & threading is done. It is used for light work and its range is 20mm to 200mm.

Turret lathe-Its function is same as central lathe but it is used for mass production. Here turret lathe is used in presence of tailstock because turret lathe contains many tailstocks. It is used for heavy duty and its range is 250mm to 300 mm.

Capstone lathe-It is belt drive. Used for light work and its range is 20mm to 150mm.


Radial arm drilling machine-It is used for drilling & boring.


Horizontal boring machine-It is computerized and used for making bore, facing etc.


Milling machine:


Horizontal milling machine It is used for making gear and cutting operations.

Vertical milling machine By this machine facing, cutting & T slot cutting is done

5. Grinder

Tool cutter grinder- Used for cutting tools and also grind them.

Hydraulic surface grinder- It consist of magnetic platform. Cooling oils are used as coolant.

Vertical grinder machine- Used for grinding purpose.

6. Hydraulic power press- Used for straightening the material. The capacity of this machine is

25 tonne.

7. Resistance brazing machine- used for overlap connections.

8. Bend saw machine- Bit is used for cutting circular object. In this machine blade width is

inch and thickness is ¾ inch.

9. Electric furnace-Used for heating the object.

10. Hydraulic punching machine-Used for making small pieces of material for desire

purpose. Range of this machine is 12mm to 250mm.

11. Hydraulic shearing machine-Used for cutting the material in range between 12mm to


COPPER SECTION-This part is only with copper cutting, bending, tinning etc.Machine

used are as listed below. Tube slitting machine-This machine is developed here & is used for cutting the tube along its length & across its diameter. Its blade thickness is 3 mm. Shearing machine-It is operated hydraulically & its blade has V-shape & a thickness of 15


Die and punching machine-It is also hydraulically operated & has a die & punch for making


Hydraulic bending machine-It is used for bending job up to 90 degree. Fly press machine- It is used to press the job. It is operated mechanically by a wheel, which is on the top of the machine. Bend saw machine -This machine is used for cutting job having small thickness. It is circularly operated blade, around 1.5 m long. Water cooled brazing machine-It contain two carbon brushes. The sheet is put along with a sulfas sheet & the carbon brushes are heated. A lap joint is formed between the sheets as the sulfas sheet melts. Linking belt machine- It creates a smooth surfaces.

Hydraulic press machine-To press the job. Solder pot machine-It has a pot that contains solder. Solder has a composition of 60% Zn & 40% Pb

TOOLING SECTION-In this section the servicing of tools is done. Blade shape machine-It sharpens the blade using a circular diamond cutter. Blade of CNC, cropping line machine is sharpened here. Mini surface grinder machine-It serves grinding purposes. It has a grinding wheel made of Aluminium Oxide. Tool & surface grinding machine-This is specially used to grind the tool used in Bay 7.


Drill grinding machine-To grind the drills.

BAY 4 & BAY-11

These are the winding section.

TYPES OF WINDING 1) Reverse section winding. 2) Helical winding 3) Spiral winding. 4) Interleaved winding. 5) Half Section winding

There are four types of coils fixed in a transformer. 1) Low voltage coil (LV) 2) High voltage coil (HV) 3) Tertiary coil. 4) Tap coil.

The type of winding depends on job requirement also the width and thickness of the conductors are designed particulars & are decided by design department. Conductors used for winding is in the form of very long strips wound on a spool, the conductor is covered by cellulose paper for insulation.

For winding, first the mould of diameter equal to inner diameter of required coil is made. The specifications of coils are given in drawing. The diameter of is adjustable as its body is made up of wooden sections that interlock with each other. Interlocking can be increased or decreased to adjust the inner diameter of coil.

The Moulds are of following types:

1. Belly types.

2. Link types.

3. Cone types.


It is core and punch section. The lamination used in power, dry, ESP transformer etc. for making core is cut in this section.

CRGO (Cold rolled grain oriented) silicon steel is used for lamination, which is imported in India from Japan, U.K. Germany. It is available in 0.27 & 0.28 mm thick sheets, 1 m wide & measured in Kg. The sheets are coated with very thin layer of insulating material called “carlites”.

Core is the basic requirements of transformer in this bay various type of lamination of core is made, they are:

Side leg- this lamination is at the extreme ends of the core which stand vertical. They are isosceles trapezium in shape with angle of 45 o .


Central leg- This as the name suggests is central vertical portion of the core. It is a diamond shaped with vertical edges longer. At the narrower edge one side is kept longer than the other for making a well fixed joint; the angles are kept 45 0 .

Yoke- The horizontal lamination of the core is called yoke. They are also isosceles trapezium in shape with angles of 45 0 .

For the purpose of cutting & punching the core three machines are installed in shop.

Slitting machine: It is used to cut CRGO sheets in different width. It has a circular cutter whose position can be changed as per the requirement.

CNC cropping line pneumatic: It contains only one blade, which can rotate 90 degree about the sheet. It is operated pneumatically.

CNC cropping line hydraulic: It is all so used to cut the CRGO Sheet. It contains two blades, one is fixed and the other rotates 90 degree above the sheet. It is operated hydraulically. M4 quality sheet 0.23-0.33 mm thickness is used.


Single traction transformer for AC locomotives is assembled in this section. These Freight locomotive transformers are used where there is frequent change in speed. They are basically used in locomotives. In this bay core winding & all the assembly & testing of transformer is done.

These three phase transformer for ACEMU are also manufactured in this section. The supply lines for this transformer are of 25 KV & power of the transformer is 6500 KVA.

The tap changer of rectifier transformer is also assembled in this bay. Rectified transformer is used in big furnace like the thermal power stations/plants (TPP).


This is the insulation shop. Various types of insulation which are to be used in transformers are prepared in this bay.


AWWW: All Wood Water Washed press paper. The paper is 0.2-0.5 mm thick cellulose paper & is wound on the conductors for insulation.

Pre-compressed board: This is widely used for general insulation & separation of conductors in the forms of block.

Press board: This is used for separation of coils e.g. L.V. from H.V. It is up to 38 mm thick.

UDEL: Undemnified Electrical Laminated Wood or Perm wood. This is special type of plywood made for insulation purposes.

Fiber glass: This is a resin material & is used in fire prone areas.

Bakelite: Size 4mm to 25 mm.

Gasket: It is used for protection against leakage.

Silicon rubber: It is used for dry type transformer.


Perma wood: Size 4mm to 25mm.



N.B.C. (Naporeniom Bonded Cork) sheets: Size 3mm, 6mm 10mm and 12mm.

The machine used for shaping the insulation material are- 1) Cylindrical machines. 2) Circle cutting machine- Used for cutting the circular objects 3) Scarping machine (used for taper cutting) & Lines in machines (to remove burrs). 4) Punching Press and Drilling machine. 5) Bench saw (specially for OD) 6) Jig saw (specially for ID) 7) Circular saw 8) Rolling machines-Used to roll the press board.


Basically two types of transformers are assembled in this bay:

Electrostatic Precipitator (ESP)

Instrument Transformers

Current Transformer (CT) up to 400kV class.

Electromotive Voltage Transformer (EMVT) up to 220kV class.

ELECTROSTATIC PRECIPITATOR (ESP) TRANSFORMERS These electrostatic precipitator transformers are used in the thermal power plants remove (precipitate) the barb on from the smoke coming out of the chimney.

ESP is of two types.

Si oil type.

Transformer oil type.

It is also known as Rectifier Transformer as it converts AC into DC.


In power lines current & voltage handled is very large & therefore direct measurement are not possible as these current & voltage are for too large for any other of reasonable size & cost. The solution lies in steeping down the current & voltage with instrument transformers that would be mattered with instruments of moderate size. The transformers are also used for protective purpose.


The main body is a bushing which also acts as insulators in which the winding is placed.

It has a top and bottom chamber.

The top chamber is the cylindrical tank of mild steel. It has terminals for connection of HV coils.


The difference between CT and PT is in their windings, i.e. in CT, primary has less turns than secondary and vice-versa.

BAY 9 & BAY-10

In these bays, power transformers are assembled. After taking input from different bays 0-8, assemblies are done. Power Transformer is used to step up & step down voltages at generating & sub-stations. There are various ratings 11 KV, 22 KV etc. manufactured, they are:

Generator Transformer

System Transformer

Auto Transformer

A transformer in a process of assemblage is called a job. The design of the transformer is done by the design department & is unique of each job; depends on the requirement of customer. The design department provides drawing to the assembly shop, which assembles it accordingly.

The steps involved in assembly are:

1) Core Building: It is made of cold rolled grain oriented steel CRGO. The punch core is sent to this shop from core punching shop. Here it is assembled with the help of drawing a set of 4 laminations is called a packet. The vertical portion of a core is called a leg. The horizontal one is caller a yoke. Packets of both are interlinked. It is undesirable to keep the X section of core circular to provide low reluctance part without air space. A perfect cannot be made so the core is steeped to achieve a near circle. Wherever the spaces are left, are fitted with thin wooden rod. After core building the end frames are bolted. The bolts are insulated from the core.

2) Core Lifting: The core is lifted by a crane & is placed vertical. The rest of the assembly is done on the core in this portion.

Unlacing & Core Coil Assembly: The yoke of this core is removed using crane. Bottom insulation in form of 50 mm thick UDEL sheets is placed PCB & press board are also used for filling the gap & to provide a good base for the coil to rest. The coil are then lowered primary, secondary, tertiary & tap in that sequences.

The following tests are done during relacing:

1. Megger test

2. Ratio test

High voltage

Testing at this stage is called pre-testing.

4) Replacing & End-frame mounting: After lowering a coil the top insulation similar to the bottom one is provided. The removed yoke is placed end-frame bolted back into its position.


The connections are then made as per drawing. All the conductors are insulated using crepe paper. Brazing copper makes the connections. For brazing sulfas is used.

5) H.V.T.G. & L.V.T.G.: Terminals gears are accessories provided at high voltage and low

voltage. Main device used is tap changer. Tap changers can be on-load or off-load. In off- load type the supply has to be tripped, then the tapings changes but in on-load type the

tapings can be changed while the

mechanism by which tapping is changed .There is switch which changes tap in very small type (Microseconds). But there is a possibility of sparking. To get rid of it, OLTC is filled with oil. The bottom part houses the terminals and the mechanism, which makes automatic

.The upper portion of the OLTC contains


connections. The terminals are made of thick Al strops.

6) Vapour Phasing & Oil Soaking: It is well known fact that water (impure) is conductor electricity. Therefore, moisture presence in transformer will affect insulation; the process of moisture removal from transformer is called vapour phasing. The job is put in dummy tank and place in a vacuum vessel. It is an airtight chamber with heating facilities. A solvent vessel is released is the chamber which enters all transformer parts and insulations. It absorbs water rapidly. The job is heated in vacuum. All the solvent vapour is sucked out with moisture and if not taken care of, may burst the job. After moisture removal tank is filled with transformer oil & soaked for at least three hours, so that every gets wet with oil. The job remains in vessel for three days during phasing. It is then taken out of the vessel & also out of the dummy tank.

7) Final Servicing & Tanking: After taking the job out of dummy tank all the parts retightened any other defects are rectified and the job is retimed in mild steel tank. After this the tanking oil is filled.

8) Case Fitting: The accessories are fixed and final touches given the job. The accessories included tank cover, fixing bushing, fixing valves etc. The terminals are marked and R and D (rating and diagram) plate is fixed by bolting and not riveting because it may require maintenance while opening and closing the tank. The bottom chamber is mild steel tank with a steel frame attached to its base for earthing.


In this shop testing on the transformer is carried out in one section and for loco in other section. In transformer testing section there are for MG sets. The electrical specifications of the entire test are given. These tests are done on demand of customer on transformer manufactured.

Here basically there are following tests conducted on power transformers:

ROUTINE TEST- It is conducted on all transformers. They are:

a) Ratio test: To determine the Voltage Transformation ratio on each tapping between HV and LV. b) Vector Group: To verify the internal connection of the coils(Windings) and the connection to the terminal. c) Winding Resistance measurement: To check the healthiness of various joints, internal connection of the coil and connection to the terminals/Bushings.



Magnetizing Current: To measure No load current at low voltage (Supply voltage)

e) Magnetic Balance: To measure flux distribution in each winding by exciting (by

applying voltage)one winding only.

f) Insulation Resistance measurement: To check the healthiness of the insulations

provided on each winding in turn to all other windings, core and frame or tank.

g) Separate source test: To check the healthiness of the insulation of each winding in turn

to all other windings, core and frame or tank with applies single phase voltage.

h) No-load loss measurement: To calculate the Power consumption during No load

condition of the Transformer itself. i) Load loss & impedance measurement: To calculate the Power consumption during full Load condition of the Transformer itself.

j) Induced overvoltage test: To verify the A.C. voltage withstands strength of each line

terminal and it’s connected winding to earth and other windings, withstand strength between phases and along the winding under test.

k) 02 KV core isolation test: To check the isolation of core.

2. TYPE TEST- These are to be conducted only on one unit of same design.

a) Temperature rise test: To observe the maximum temperature when the transformer is

running on continuous full load.

b) Impulse test: To verify the A.C. voltage withstands strength of each line terminal and

it’s connected winding to earth and other windings, withstand strength between phases and along the winding under test. This test is conducted at a voltage even higher than induced overvoltage.

c) Auxiliary loss test: To measure the power taken by cooling gear like Fans & pumps.

d) Acoustic Noise level measurement: To measure average sound level generated by the

Transformer when energized at rated voltage and rated frequency at no load.

e) Zero sequence impedance measurement: To calculate the impedance when all

three phase are symmetric.

f) Short time current test (STC test)



. Polarity test:

Instrument used: Polarity meter analog multimeter.

One of the winding is supplied with 1.5V D.C. supply and the other is connected to ammeter. If the direction of the deflection is correct implies the connections are correct else it is wrongly connected.

Accuracy test:

It is the test for checking the turn ratio steps:

A standard transformer primary is connected across the primary of the job.

As the no. of turns of the secondary transformer is known the no. of turns of secondary of job is calculated.

The ratio is taken and the max permissible error should be not more than that specified by the design.

Even the phase angle is checked for this max permissible limit.


Inter turn insulation test:

Checks for the insulation of the transformer

Current is given to primary and secondary is open circuited.

Either of the rated primary current or the 4.5KV peak secondary voltages whichever appears first is allowed to withstand for 1 min.

Then if the insulation can withstand then it is said to be okay.

Winding resistance:

Error in winding resistance appears if the conductors of different length are used if the

conductors are joined in between to check this winding resistance is checked and if it appears then the internal points of connections is changed.

One minute power frequency (dry) withstand test-It is the high voltage test used to check the insulations on primary and secondary. It depends upon the line voltage system for primary. And for secondary it is 3 or 5 kV rms as applicable.

Tan d test- It is conducted to justify the quality of insulation. Its limit is 0.005 at Um/ .

Partial discharge test- It is used to justify the manufacturing process. Its limit is 10 pc at 1.1Um/.


Temperature rise test

Short time current test (STC test)-It is conducted only on CT.

Short time withstand capability test- It is conducted only on VT.

Impulse test

One minute power frequency wet withstand test- It is conducted in rainy conditions to check the external insulations.


The objective of this department is to interact with the customers. It brings out tenders & notices & also responds to them. It is department that places the contracts of building the transformers & after delivery further interacts with the customer regarding faults, this department does failure & maintenance. All such snags are reported to them & they forward the information to the concerning department.

The works of the commercial department are:

Tenders and Notices.

Interaction with design department

Place of work

Approximate cost of work

Earnest money

Place and time where document can be seen.

Amount if any to be paid for such document.

Tenders and notices: The department response to the tenders calls of companies/organization, which requires transformers. Contracts are bagged through also notices. Before inviting tenders


it must be sure that BHEL is ready to undertake the contract and before full knowledge of scope of work is essential.


The transformers manufactured in BHEL Jhansi range from the 100MVA to 315MVA and up to 400kV.The various transformers manufactured in this unit are:

Power Transformer

Generation transformer

System transformer

Auto transformer

Special Transformer

Freight loco transformer

ESP transformer

Dry Type Transformer

All above types are oil cooled except dry type, which is air cooled.

The designing of all these transformers is done by the TRE department according to the specifications of the customers’ i.e.

1. The input/output voltage.

2. The KVA rating.

3. The weight of iron and copper.

The basic design factors are:

1. The amount of copper and iron losses.

2. The rise in temperature of coils.

3. The ambient condition.

The designer has to keep rise between the design factors and selects the optimization of the core yoke winding etc.

Functioning of TRE

Tendering/Submission of offer with EFC

Study of customer specifications


Preparation of material sheet

EFC(Estimated Factory Cost)

Guaranteed technical particulars with tender drawings

Type test reports of similar equipments

Deviation/clarification etc.


Contract execution


Electrical Specification

Guaranteed technical particulars*

Testing schedule*

Customer Drawings*

Components Drawings etc.

Indenting of Materials

Manufacturing information to shops

Shipping instruction for transportation

*Approval required from customer


This department analysis the changes taking place in the world and suggest changes and upgrades accordingly. This section mainly deals with continuous modification in the operations to be performed for the completion of the job. It gets the PSR (Performa of Specification & routine Sheet) from PPC. This is very important department because the product must not get obsolete in the market otherwise they will be rejected by the customer.

This section gives the sequence of operations, time for operations, no. of labors etc., according to the given standards; it can be modify the above things to obtain best results.


Technology functions can be classified as:

Processing Sequence: The sequence of process of manufacturing is decided for timely and economic completion of the job.

Operation Time Estimate: It includes incentive scheme management.

Allowed Operation Time: It includes incentive amount.

Facilities Identification: It includes looking for new equipment or plant or tools to increase productivity.

Special Process Certification: special processes are the ones requiring expertise for example identifying errors, cracks, air bubbles in the welding.

Special Tools Requirement: special tools are allotted, if possible, when required else the design has to be reconsidered.

Productivity Projects compilation: It includes the initial analysis of the problem and their appropriate solution to enhance productivity


Recently it has modified the operation of crimping in which it advised the use of tungsten carbide thus reducing the work time to three hours instead of 27 hours with HSS; this also relieved the workers from maintenance of different dies for different jobs. The principle of working is that




This unit was started in 1985.

A locomotive is a rail vehicle that provides the motive power for a train.

“LOCO” means from a place.

“MOTIVE” means causing motion.

A locomotive has no payload capacity of its own. It is used to move a train.

This department of Jhansi consists of two sections the first is manufacturing & other is design.

The diesel, AC, AC/DC locomotives are manufactured here.


Salient features:

a) Flat bed under frame.

b) All pneumatic valves provides in single panel.

c) All electrical Equipments provided in single panel.

d) Improved filtration system.

e) Brush less traction alternators.

f) Fault display on control desk with alarm.

g) Simple driving procedure.

h) Automatic wheel slip detection & correction.

i) Multiple unit operation up to three locomotives.

j) Air & vacuum brakes.


Salient features:

a) Operate on 25 KV AC Single-phase lines.

b) Driving cab at both ends.

c) Corridors on both sides for maintenance.

d) All pneumatic valves at one place.

e) Automatic wheel slip detection & correction.

f) Multiple unit operation up to three locomotives.

g) Fault display on driver’s desk.

h) VCB in AC circuit.

i) Air & Vacuum brakes.

THE AC/DC LOCOMOTIVE Salient features:

Designed to operate both in 1500 V DC & 25 KV AC lines.


Driving cab at both ends.

High adhesion bogie.

Corridors on both sides for maintenance.

All pneumatic valves at one place.

Automatic wheel slip detection & correction.

Multiple unit operation up to three locomotives.

Fault display on driver’s desk.

Static inverter for auxiliary supply.

FRP control desk.

VCB in AC circuit.

Air & Vacuum brakes.

Air dryer for brake system.


There are following products are manufactured at Loco shops

Alternating Current Locomotive (ac Loco)


AC./D.C. Loco



W-broad gauge

C-running in DC mode

P-hauling passenger train

A-running in AC mode

G-hauling goods train

M-hauling passenger & goods train

Diesel Electric Locomotive Shunting (DESL)

350 HP

700 HP

Single Power Pack (SPP): One 700 HP m/c is made as a single

Unit. It is a meter gauge locomotive


Twin Power Pack (TPP): 2 350HP m/cs are combined in 1 engine & can be operated individually or in combination depending on the load.

450 HP

1400 HP

1150 HP

1350 HP

2600 HP

1150 HP and 1350 HP DESL s are non-standard locomotives and are modified versions of 1400 HP DESL based on requirement of customer.

Under mention are the new non-conventional products designed and developed for Indian Railways based on their requirement.

OHE (Overhead electric) recording and testing cars

UTV(Utility vehicle )

RRV(Rail cum road vehicle)

DETV( Diesel electric tower car)

BPRV(Battery power road vehicle)

BCM(Blast cleaning machine)

200 T Well wagon for BHEL Haridwar

Metro Rake-Kolkata Metro Railway


This section deals with manufacturing of locomotives. The main parts of the

locomotive are

Under frame: The frame on which a locomotive is built

Super structure: The body of locomotive is called superstructure of sheet of Mild steel

DC motor


or Shell and is made




Static Rectifier-MSR

Static Converter-SC


Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially contains

1-wheel axle arrangement


3-Brake rigging

Traction transformer: It is fixed on under frame and gets supply from an overhead line by equipment called pantograph. The type of pantograph depends on supply. This transformer steps down voltage and is fitted with a tap changer. Different taps are taken from it for operating different equipment. One tap is taken and is rectified into DC using MSR and is fed to the DC motor.

Railways has two types of power supplies 25 KV , 1 Phase ,50hz AC

-1500 V DC

An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.


First we get acquainted with a few terms concerning this department. Quality: It is the extent to which products and services satisfy the customer needs. Quality Assurance: All those plants and systematic action necessary to provide adequate confidence that a product or service will satisfy the given requirement is called quality assurance. Quality control: The operational techniques and activities that are used to fulfill requirement for quality are quality controlled. Quality Inspection: Activities such as measuring, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity are termed as Quality Inspection.


As the name suggest this section deals with services & maintenance. It has following sections:

Plant equipment: This has electronics & elect/mech. Maintenance.


Services: This section deals with air, steam & Power equipments.

Telephone Exchange.

Township Electrical Maintenance.

W.E. & S Planning.

This sections deals with stores & new machines procurement & other general things. There are three maintenance centers at bay-2, substation 1 & Loco. This section is also responsible for Power distribution in B.H.E.L. The power distribution is of two types:

1) HT Power Distribution: This is at 11 KV, OCB are used for protection. There are four substations for this distribution. 2) LT Distribution: This is for the auxiliary in each shop & other section of B.H.E.L. It uses OCB/OVC/BHEL BHOPAL, 800 KVA 415V Transformer & ACB (English Electro).

This department looks after the commissioning and maintenance of all the machinery used in the factory. It also has 3 two-stage air compressors for supplying compressed air to the various bays.

The department has 03 different divisions:

Electrical Engg

Electronics Engg

Mechanical Engg


This division looks after all the electrical machinery and power distribution of the factory. Snags detected in the system are immediately reported to this dept by the concerning dept.WE&S takes prompt action to rectify it.

The factory has a feeder of 11KV .The total load sanctioned for the factory is 2500MVA But the maximum demand reaches the range of 1700-2000 MVA.

Here are various sub-stations (SS) inside the factory, for distribution of power to different sections.

SS -1


Bay-6 to Bay 9

SS -3


Bay 1to Bay-4

SS -4


Boiler and loco plant

SS -5


Bay -5

SS -6


Administrative building






The term 'Power Transformers’ refers to the transformers used between the generator and the distribution circuits, and these are usually rated at 500 kVA and above. Power systems typically consist of a large number of generation locations, distribution points, and interconnections within the system or with nearby systems, such as a neighbouring utility. The complexity of the system leads to a variety of transmission and distribution voltages. Power transformers must be used at each of these points where there is a transition between voltage levels. Power transformers are selected based on the application, with the emphasis toward custom design being more apparent than larger the unit. Power transformers are available for step-up operation, primarily used at the generator and referred to as generator step-up (GSU)

transformers; step-down operation, mainly used end to feed distribution circuits and to connect grids operating at different voltage levels through interconnecting transformers. Power transformers are available as single-phase or three-phase apparatus. Power transformers have been loosely grouped into three market segments based on size ranges. These three segments are:

1. Small power transformers 500 to 7500 kVA

2. Medium power transformers 7500 to 100 MVA

3. Large power transformers 100 MVA and above.



A transformer is a static piece of apparatus used for transferring power from one circuit to

another without change in frequency. It can raise or lower the voltage with a corresponding decrease or increase in current. In its simplest form, a transformer consists of two conducting coils having a mutual inductance. The primary is the winding which receives electric power, and the secondary is the one which may deliver it. The coils are wound on a laminated core of magnetic material. The physical basis of a transformer is mutual inductance between two circuits linked by a common magnetic flux through a path of low reluctance. The two coils possess high mutual inductance. If one coil is connected to a source of alternating voltage, an alternating flux is set up in the laminated core, most of which is linked up with the other coil in which it produces mutually induced emf (electromotive force) according to Faraday's laws electromagnetic induction, i.e. e =

where, e = induced emf M = mutual inductance

If the second circuit is closed, a current flows in it and so electric energy is transferred (entirely

magnetically) from the first coil (primary winding) to the second coil (secondary winding).



Losses in transformers are:

No-Load Losses It includes both hysteresis loss and eddy current loss. As the core flux in a transformer remains practically constant at all loads, the core-loss is also constant at all loads.

Hysteresis loss



Eddy current loss Watts


Where = the hysteresis constant = the eddy current constant = the form factor These losses are minimized by using steel of high silicon content for the core and by using very thin laminations. The input power of a transformer, when on no-load, measures the core-loss.

Load Losses This loss is mainly due to the ohmic resistance of the transformer winding. Copper-loss also includes the stray loss occurring in the mechanical structure and widening conductor due to the stray fluxes. Copper-loss (-loss plus stray loss) is measured by the short-circuit test.

THREE-WINDING TRANSFORMER Purpose A transformer may have additional windings apart from the two conventional main windings depending upon the particular application and type of connection (of the main windings). In

three-winding transformers, the third winding is normally called as tertiary winding and it is provided to meet one more of the following requirements:

(a) For an additional load which for some reason must be kept isolated from that of secondary. (b)To supply phase-compensating devices, such as condensers, operated at some voltage not equal to primary or secondary or with some different connection (e.g. mesh).


In star/star-connected transformers, to allow sufficient earth fault current (zero-sequence component current) to flow for operation of protective gear, to suppress harmonic voltages and to limit voltage unbalance when the main load is asymmetrical, the tertiary winding is delta-connected.


As a voltage coil in a testing transformer.


To load charge split winding generators.


To inter-connect three supply systems operating at different voltages.


Apart from active materials like copper and cold rolled grain oriented silicon steel, a number of ferrous, nonferrous and insulating materials are employed for building up a transformer. Optimum utilization of all materials in consonance with their electrical, mechanical, physical, chemical and thermal characteristics is necessary for obtaining a compact size transformer. One


basic requirement for all materials used in an oil-filled transformer is that they should be compatible with insulating oil and should not react with or deteriorate oil. Table 1 gives application, applicable national and international standards of various materials used in a transformer.


Insulating oil forms a very significant part of the transformer insulation system and has the important functions of acting as an electrical insulation as well as a coolant to dissipate heat losses. The basic raw material for the production of transformer oil is a low-viscosity lube termed as transformer oil base stock (TOBS), which is normally obtained by fractional distillation and subsequent treatment of crude petroleum. Important characteristics of TOBS given in Table 2 must be kept within permissible limits in order to produce good insulating oils. TOBS is further refined by acid treatment process to yield transformer oil.

Materials Used in Power Transformer

Sl. No.


Applicable Standards and Grade


Insulating Materials

1. Transformer oil

2. Electrical grade paper

IS : 335, BS : 148 IEC 60296

Liquid dielectric and coolant


Kraft insulating paper

IEC 60554-3-1

Layer winding air insulation,

of medium permeability

condenser core of oil impregnated bushing.

Kraft insulating Paper of high air permeability

IEC 60554-3-1

Covering over rectangular copper conductor covering over continuously transposed copper conductor covering over stranded copper cable

Crepe Kraft paper

BS 562633

Covering over flexible










Sl. No.


Applicable Standards and Grade




Press Paper

kraft Paper with

aluminium bands


Crepe kraft paper with aluminium foil Pressboard

Pressboard moulding from wet sheet or wet wood pulp

Soft calendered pressboardsolid

IS : 8570, BS : 3255

Backing paper for axial cooling duct

Base paper as per above

Base paper as per (i) above


Line and common shield

in winding

IEC 6064131

Type C of IS : 1576 IEC : 6064131

Angle ring, cap, sector, snout, square tube, lead out and moulded piece of intricate profile for insulating ends of windings, insulation between windings and numerous other applications. Cylinder, barrier, wrap, spacer, angle washer, crimped washer and yoke

iii. Soft pressboardlaminated

BS EN 607631.2

insulation etc. Block, block washer, terminal gear cleat and support, spacer, etc.


IEC 606413.2

Dovetail block and strip,


clack-band, cylinder, warp, barrier, spacer, block, block washer, corrugated sheet, yoke bolt, washer etc.

v. Precompressed pressboard laminated

IEC 607633.1

Top and bottom coil clamping ring, block, block washer, dovetail strip, spacer etc.

4. Wood and laminated wood i. Unimpregnated densified laminated woodlow density

IEC : 61061

Cleat and support, core/yoke clamp, wedge block, winding support block, sector, core to coil packing etc.


ii.Unimpregnated densified laminated woodhigh density

IEC : 61061

Coil clamping ring, block, cleat support etc.

Sl. No.


Applicable Standards




and Grade

5. Insulated copper

conductor and cable i. Paper covered rectangular copper conductor

IEC : 60317 IS : 13730

For making different types of windings.

ii. Paper covered continuously transposed copper conductor

IEC : 60317

For making different types of winding.

iii. Paper covered stranded copper cable

iv. Crepe paper covered flexible copper cable

IS : 8572 conductor to IS : 8130,

IEC : 60228

Conductor to IS : 8130, IEC : 60228

For making lead and terminal

For making lead and terminal required to be


IS : 1554, BS : 6346

v. PVC insulated copper cablesingle and multicore

IEC : 60502

bent to a small radius. Control wiring in marshalling box, nitrogen sealing system.

Insulating Tape i. Cotton tape

IS : 1923

For various taping purposes.

ii. Cotton newar tape

For taping and banding

iii. Glass woven tape

IS : 5352, IEC : 610671

Used in core bolt insulation

iv. Woven terylene tape

IS : 5351, IEC : 610681

For taping purposes at places requiring higher strength

v. Polyester resin impregnated weftless glass type

Banding of transformer cores


Phenolic laminated paper base sheet

IS: 2036, BS:2572

Terminal-gear support and cleat, gap filler in reactor, tap changer components


Phenolic laminated cotton fabric sheet

IS:2036, BS: 2572

Terminal board, for making core duct,

Sealing Materials

support and cleat.


Synthetic rubber bonded cork

IS: 4253 (Part II)

As gasket in different places to prevent oil leakage from joints viz.


10. Nitrile rubber sheet and moulding

Ferrous Materials

11.Cold rolled gain oriented silicon steel (CRGO) 12.Cold rolled carbon steel sheet

BS: 2751

BS: 6404/ASTM A876M/ DIN 46400 IS: 513 ASTM A620 M BS: 14491.1

Sl. No.

Applicable Standards Application and Grade


tank rim, turret opening, inspection cover and with mounting flange of various fittings etc. As gasket in different places to prevent oil leakage from joints, 'O' ring in bushings, moulded component in fittings.

For making transformer core For making radiator

13. High tensile strength structural steel plate

IS: 8500

Core clamp plate, anchoring and clamping core to bottom tank

14. 1.5% nickel- chromiummolybdeum steel bar and sections hardened and tempered

IS: 5517

Lifting pin, roller shaft

15. Austenitic chromium nickel steel titanium (stainless steel )

IS: 6911, BS: 1449

Turret opening, non- magnetic insert, etc. to stabilized plate neutralize the effect of eddy currents

16. Stainless steel sections (austenitic)

IS : 6603, BS : 970

Non magnetic bar for high current applications.

17. Structural steelstandard quality (plate, section, flat, bar, channel, angle, etc.)

IS : 2062

Tank, end frame, clamp plate, 'A' frame for radiator, conservator, turret, cable box and for other structural purposes.

18. Bright steel bar and

IS: 7270

Threaded and machined


sectionscold drawn

Non-Ferrous materials Sl. No.



19. High conductivity copper


Applicable Standards and Grade

i. Sheet, strip, foilhard

IS : 1897

For various current

and soft

carrying applications,


IS : 613

e.g. bushing


BS : 1977

conductor, terminal

Casting and forging

BS : EN 1982

lead, divertor and

Tinned foil

IS : 3331

selector contacts of

Flexible cable

IS : 8130, IEC : 60228

on-load tap changers,

vii. Flat flexible braid

winding shield, cable box components, off- circuit switch items, etc.

20. Copper alloys

i. Free machining brass

IS: 319

Tie rod and for

rod, square and hexagon ii. Phosphor bronze rod

IS: 7811

making different components. Tapchanger components

iii. Nickel silver strip

IS: 2283

For making winding shield

21. Aluminium

i. Aluminium alloy plate

ii. Aluminium plate (99.0 percent) iii. Aluminium foil

Alloy 54300 M (NP 8M) of IS : 736

Alloy PIC of IS : 736


Flange in bushing, cable box, other non- magnetic applications Shielding of reactor tank, Condenser layer in bushings

Fig.1. Insulation items WINDINGS AND INSULATIONS Windings form the electrical circuit of a transformer. Their

Fig.1. Insulation items


Windings form the electrical circuit of a transformer. Their construction should ensure safety under normal and faulty conditions. The windings must be electrically and mechanically strong to withstand both over-voltages under transient surges, mechanical stress during short circuit and should not attain temperatures beyond the limit under rated and over-load conditions. For core-type transformers, the windings are cylindrical, and are arranged concentrically. Circular coils offer the greatest resistance to the radial component of electromagnetic forces, since this is the shape which any coil will tend to assume under short circuit stresses.


The choice of the type of windings is largely determined by the rating of the winding. Some of the common types of windings are described below.


This type of winding is normally used up to 33 kV and low current ratings. Strip conductors are

wound closely in the axial direction without any radial ducts between turns. Spiral coils are normally wound on a bakelite or pressboard cylinder (Fig. 4).

are normally wound on a bakelite or pressboard cylinder (Fig. 4). Fig.3. Spiral coil (single layer,

Fig.3. Spiral coil (single layer, wound on flat side)


Though normally the conductors are wound on the flat side, sometimes they are wound on the edge. However, the thickness of the conductor should be sufficient compared to its width, so that the winding remains twist-free (Fig. 5)

its width, so that the winding remains twist-free (Fig. 5) Fig.4. Spiral coil (edge wound) Spiral

Fig.4. Spiral coil (edge wound)

Spiral windings may be made as single layer or multilayer type. In a double-layer spiral coil where oil duct separates the two layers. For such a coil, both the start and the finish leads lie at one end of the coil and may at times prove to be advantageous for making the terminal gear. Normally it is not necessary to provide any transposition between the parallel conductors of a spiral winding as the lengths and the embracing of leakage flux are almost identical.


This type of winding is used in low-voltage and high-current ratings. A number of conductors are used in parallel to form one turn. The turns are wound in a helix along the axial direction and each turn is separated from the next by a duct. Helical coils may be single-layer (fig. 5) or

double layer (fig. 6) or multi-layer, if the number of turns is more.

(fig. 6) or multi-layer, if the number of turns is more. Fig.5. Helical coil (Single layer)

Fig.5. Helical coil (Single layer)

Fig.6. Helical coil (Double layer)


This type of winding is used for voltage between 33 and 132 kV and medium current ratings. These coils consist of a number of sections placed in the axial direction (fig. 7), with ducts between them. Each section is a flat coil, having more than one turn, while each turn itself may comprise one or more conductors (usually not more than four or five), in parallel. The sections


are connected in series, but without any joints between them. This is achieved by a special method of winding. It is not necessary to provide a cylindrical former for these coils, as these are self supporting. Each disc is mechanically strong and exhibits good withstand of axial forces. The layer depth or LD of the winding is defined as the number of turns of segments available in the section. Another particular advantage of these coils is that, each section can have either integral or fractional number of turns (for example turns per section). Once the number of turn is given, rest of the segment in that section is provided with packing to maintain LD.

in that section is provided with packing to maintain LD. Fig.7. Continuous disc winding Fig.8. Arrangement

Fig.7. Continuous disc winding

with packing to maintain LD. Fig.7. Continuous disc winding Fig.8. Arrangement of continuous disc winding This

Fig.8. Arrangement of continuous disc winding

This is also known as R-S or reverse section coil because one section is given the reverse winding while one section is given forward winding.


These kinds of coils can be classified on the basis of winding direction, if the winding is started

by rotation of conductors in clockwise direction i. e. known as standard half sectional coil whereas anticlockwise rotation is termed as non-standard half sectional coil. The brazing leads required in some cases of the transformer are also provided in this kind of coil.



disadvantage with the continuous disc winding is that their strength against impulse voltages


not adequate for voltages above, say, 145 kV class. The impulse voltage withstand behaviour

of disc coils can be increased if the turns are interleaved in such a fashion that two adjacent conductors belong to two different turns. Fig.9. shows such a winding, in which interleaving has been done. It will be noticed that it is necessary to have 2n conductors in hand for winding


when n in the number of conductors in parallel. Conductors of turns 8 and 9 are joined by brazing. A cross-over is given at the bottom of the disc.

by brazing. A cross-over is given at the bottom of the disc. Fig.9. Interleaved disc winding

Fig.9. Interleaved disc winding (4 discs per group)

This gives further improved behaviour against impulse voltage, though there are concomitant increased complexities. Interleaved windings require more skill and labour than plain continuous disc windings. Sometimes a part of the winding is interleaved while the remaining part is plain disc, so as to combine the advantages of better impulse withstand at the high voltage end of the winding and reasonable labour cost for the winding as a whole. These are known as partially interleaved windings.


In this kind, more than one coils are winded on the same mould. These are generally used for the purpose of tapped coils.


Transposition- In order to make the length of all the conductors in a winding, the position of each conductor is varied symmetrically. This is known as transposition. Unless transposed, the conductors within a coil do not have the same length and same flux embracing and therefore have unequal impedance, resulting in eddy losses due to circulating current between the conductors in parallel. To reduce these eddy losses, the helical windings are provided with transposition of the conductors which equalise the impedances of the parallel conductors.

ID-This is known as the inner depth or diameter of the coil. This is basically the width of the base on which the conductors are wounded.

OD-This is known as outer depth or diameter of the coil.

LD-It is known as layer depth.


CD-It is known as CD. It is the length measured from starting lead point to the finishing lead point.

MD-This is known as mould diameter and is same as ID.

 MD- This is known as mould diameter and is same as ID. Fig.10. Winding in

Fig.10. Winding in progress horizontal lathe


In a transformer, energy is transferred from one electrical circuit to another through the

magnetic field. Transformer core made of laminated sheets provides the magnetic circuit for the flow of magnetic flux mutually linking the electrical circuits. As against the air core, iron core provides a comparatively low reluctance path to the magnetic flux with consequent benefit of


Smaller magnetizing current,


Increase in the total flux linkage and


A high ratio of mutual to leakage flux resulting in reduction of stray losses.

Its design, type and manufacturing methods have significant bearing on quality, transportability, operational limitations and guaranteed technical performance of the transformer.


CRGO (Cold Rolled Grain Steel) is used to build the core. It has the minimum Epstein losses to the flow of magnetic flux along the directions of grain orientation. CRGO is used to reduce the hysteresis losses and the lamination made out of these sheets minimizes the eddy’s current losses. Both surfaces of the core steel sheets are provided with an insulating of oxide coating (commercially known as Carlite). The stacking factor of lamination improves by using thicker


laminations, but eddy current loss goes up in proportion to square of the thickness of the lamination. For reducing the eddy current losses, thinner laminations are preferable even though the stacking factor goes down. Deburring of the laminations improves the stacking factor and minimizes the eddy losses.


For a transformer design, the basic governing factors are:


Rating of transformer and its performance.


Operational conditions,


Transport limitations (i.e. height, length, width and weight etc.)

The design of the magnetic circuit, i.e. transformer core is also based on the above considerations and it has significant bearing on the overall economy of the transformer. For CRGOS, saturation may occur at the magnetic flux densities exceeding 1.9 tesla. Based on the input voltage and frequency variations, a suitable value of flux density can be adopted to avoid any chance of core saturation under operating conditions. By increasing the operating value of magnetic flux density (magnetic loading) the net weight of core can be reduced, but this leads to corresponding increase in the core losses. One has to compute an optimum value of the

magnetic flux density, keeping in view all the above considerations. Constructional Features The type of transformer core construction depends on the technical particulars of the transformer and transport considerations. In general it is preferable to accommodate the windings of all the three phases in a single core frame. Three phase transformers are economical over a bank of three single-phase transformers. Another important advantage of three-phase transformer cores is that component of the third and its multiple harmonics of mmf cancel each other, consequently the secondary voltage wave

shape are free from distortions due to the third harmonics in mmf. However, if the three-phase ratings are large enough and difficult to transport, one has no choice but to go for single-phase transformer units. For single-phase and three-phase transformers, the cores can be broadly classed as:


Single-phase three-limbed core


Single-phase two-limbed core


Three-phase three-limbed core


Three-phase five-limbed core


BURR LEVEL: The sheets undergo proper cutting and is then available in many shapes like trapezoidal, octagonal, hexagonal etc. But while cutting the edges of these sheets, there is some generation of rough surfaces which are known as burr level. The formation of these levels should be avoided because they produces air gap which increases the losses. To control the burr level, the cutting of CRGO is done with the help of CNC(Computer Numeric Control) machines.


Fig.12. CNC and core assembly CORE ASSEMBLY Core building from the finished lamination sheets is

Fig.12. CNC and core assembly


Core building from the finished lamination sheets is done in horizontal position on specially raised platforms. The lamination sheets are susceptible to mechanical stresses of bending, twisting, impact, etc. A lot of care is exercised while handling and normally two persons are needed to hold the two ends of the laminations at the time of laying. At first the clamp plates and end frame structure of one side of the core assembly are laid out. Guide pins are used at suitable positions for maintaining the proper alignments during core building process. Oil ducts are formed by sticking strips on lamination and put in position as required. For each packet, the laminations are manufactured in two different lengths and these sets are laid out alternately, keeping at a time two to four laminations together. The two alternate arrangements provide overlapping at the corner joints and when the lamination packets are clamped together, these overlapping edges provide sufficient mechanical strength in holding the edges in tight grip. After laying out the complete laminations, the clamp plates, and end frame structure of the other side are laid out and the entire core-end frame structure is properly secured through bolts and steel bands at a number of positions. The platform on which the core building takes place is of special design and the core-end frame assembly can be raised to the vertical position along with the platform which serves as a cradle. Subsequently the platform is disengaged. In this process, the core assembly is spared from the mechanical strain of lifting and raising in the vertical position. Small-size cores can however be built up without these special platforms. Steel bands used for tightening the laminations is only a temporary arrangement and are later removed, otherwise these will form short circuited turns. Two commonly used methods of holding the leg laminations together is their clamping by either resiglass tape or using skin stressed bakelite cylinders.


In case of resiglass tapes, these are tightly wound around the legs at specified pitch and cured by heating. The tape shrinks after heating and provides a firm grip. The tensile strength of resiglass tapes is even higher than that of steel tapes. In the case of core legs tightened by skin stressed cylinders (base cylinder of innermost coil), these are lowered from the top and the steel bands and cut progressively. Wooden wedges are inserted along the packet corners and hammered down, so that the enveloping bakelite cylinder and the leg laminations are fitting tightly against each other. Conventionally, the core is assembled along with all the yokes, and after assembly the top yokes are unlaced after removing the top-end frames for the purpose of lowering the windings. This takes a lot of labour and manufacturing time. The latest development is to assemble the core without top yokes and insert the top yokes after lowering all the windings in the core leg.

top yokes after lowering all the windings in the core leg. Fig.13. Core assembly process FITTING
top yokes after lowering all the windings in the core leg. Fig.13. Core assembly process FITTING

Fig.13. Core assembly process

FITTING OF CORE IN THE TANK The most commonly used method of putting the core assembly is to rest the core frame on its feet, which in turn is firmly fixed on the tank base. The extreme end feet are enclosed in a steel bracket welded on the tank base. The top portion of core assembly is also suitably locked with the tank cover, so that any possible magnification of the vibration during transit is fully arrested. An alternative to this is construction of the tank base in the shape of a channel. The


laminations along with the bottom-end frames are jacket from either side against the channel walls of the tank. As such, no bolts are needed in the bottom yokes and iron losses are comparatively lower.


The device tapchanger is used for adding or cutting out turns of primary or secondary winding of the transformer. Basically tap changing equipment can be divided in two categories. 1. OFF-CIRCUIT TAPCHANGER The cheapest method of changing the turn ratio of a transformer is the use of off circuit tapchanger. As the name implies, it is essential to de-energize the transformer before changing the tap.

An off-circuit tapchanger, as shown in Fig. 12, consists of principally the following three parts:


Operating handle projecting outside the transformer.


Fixed contact with connecting terminal


Insulating shaft with moving contact system.

The basic transformer winding circuit arrangements using off-circuit tapchanger are:











Depending upon the requirement, any of the above arrangements of the winding can be made use of to get desired voltage regulation. To prevent unauthorized operation of an off-circuit tapchanger, a mechanical lock is provided. Also to prevent inadvertent operation, an electromagnetic latching device or microswitch is provided to open the circuit breakers to de-energize the transformer while operating the handle

of tapchanger before movement of contacts on tap switch.

to de-energize the transformer while operating the handle of tapchanger before movement of contacts on tap


Fig.14. Off load tapchanger 2 . ON-LOAD TAPCHANGER (OLTC) On-load tapchangers are employed to change

Fig.14. Off load tapchanger

2. ON-LOAD TAPCHANGER (OLTC) On-load tapchangers are employed to change turn ratio of transformer to regulate system voltage while the transformer is delivering normal load. With the introduction of on-load tapchanger, the operating efficiency of electrical system has considerably improved. Now-a- days, almost all the large power transformers are fitted with on-load tapchanger. All forms of on-load tapchanging circuit posses an impedance, which is introduced to prevent short circuiting of tapping section during tapchanger operation. The impedance can be either a resistor or centre-tapped reactor. The on-load tapchanger can in general, be classified as resistor or reactor type.

can in general, be classified as resistor or reactor type. Fig.15. On-load tapchanger COOLING ARRANGEMENTS In

Fig.15. On-load tapchanger


In power transformer, the oil serves a dual purpose as an insulating medium as well as a cooling medium. The heat generated in the transformer is removed by the transformer oil surrounding the source and is transmitted either to atmospheric air or water. This transfer of heat is essential to control the temperature within permissible limits for the class of insulation, thereby ensuring longer life due to less thermal degradation.


ONAN Type Cooling In case of smaller ratings of transformers, its tank may be able to dissipate the heat directly to the atmospheric air. In these cases, the heat dissipation is from transformer oil to atmospheric air by natural means. This form of cooling is known as ONAN (oil natural, air natural) type of cooling. ONAF Type Cooling


For further augmenting the rate of dissipation of heat, other means such as fans blowing air on to the cooling surfaces are employed. The forced air takes away the heat at a faster rate, thereby giving better cooling rate than natural air. This type of cooling is called ONAF (oil natural, air forced) type of cooling. In this cooling arrangement, additional rating under ONAN condition viz. after shutting off fans, is available, which is of the order of 70-75%. OFAF Type Cooling Still better rate of heat dissipation could be obtained if in addition to forced air, means to force circulate the oil are also employed. The oil can be forced within the closed loop of transformer tank and the cooling equipment by means of oil pumps. This type of cooling is called OFAF (oil forced, air forced) type of cooling. Mixed cooling transformers of radiator type can have two or three ratings available, one for each type of cooling, viz, OFAF, ONAF and ONAN. OFWF Cooling Since the ambient temperature of water is always less than the atmospheric air, it is possible to use water as a better heat-transfer media. Such an arrangement employs oil to water heat exchangers. A prerequisite for such an arrangement is the availability of a source of sufficient quantity of water. In most of the transformers for hydropower stations, this type of cooling is used. Such a cooling is called OFWF (oil forced, water forced) type of cooling. Forced Directed Oil Cooling Additional means of improving the heat dissipation rate are also employed on higher ratings for transformer. These comprise arrangements which direct the transformer oil in the windings through predetermined paths. This directed oil flow type of cooling is utilized with advantage in case of forced oil system. The cool oil entering the transformer tank from the cooler/radiators is passed through the windings in a pre-decided manner ensuring faster rate of heat transfer. This type of cooling is called ODAF (oil directed, air forced) or ODWF (oil directed, water forced) type.


SPECIFICATIONS OF TRANSFORMER- Complete specifications must be furnished for designing the transformer to suit the specific requirements. In the following paragraphs design procedure, selection of various parameters and their effect on the various performance criteria has been discussed.

SELECTION OF CORE DIAMETER- Core diameter of a transformer depends upon a number of factors like rating, percentage impedance between windings, basic insulation level, transport height, overfluxing requirements, type of core and quality of core steel. Based on this, guaranteed parameters, viz percentage impedance and losses are worked out. Core diameter is adjusted to meet the guaranteed parameters.

Influence of Varying Core Diameter- Increasing core diameter increases area of cross- section, thereby increasing voltage per turn, which reduces the number of turns in various windings. The percentage reactance between windings is directly proportional to number of turns and diameters of various coils and is also inversely proportional to volts per turn and coil depth. In order to have specified reactance, increased core diameter necessitates


reduction in coil depth and increase in coil dimensions in lateral direction, which leads to reduction in core height and increase in core leg centres. Inspite of reduction in core height due to increase in core diameter, overall weight of core steel increases, which also increases no-load loss of transformer. Also, reduced number of turns in windings even with larger length of mean turn results in reduced copper weight, which in turn also reduces the load loss of transformer. Similarly, reduced core diameter results in reduced core steel weight and no-load loss increased copper weight and load loss.

Core Area- Stepped core construction is used to obtain an optimum core area within circumscribing circle of a core. Core area depends upon number of steps, grade of core steel, insulation on the laminations, i.e. varnished or unvarnished, and method of core clamping. As the number of steps increases, core area also increases, however it needs extra labour to cut the various sizes of laminations. Optimum numbers of steps are used to give overall economy. Large rating transformers are usually provided with high tensile steel clamp plates for clamping the core laminations, which provide increased core area for a particular core diameter. Depending upon the flux density in the core, adequate numbers of ducts are provided to keep its hot-spot temperature and cooling ducts in core.

SELECTION OF FLUX DENSITY- Normally flux density is chosen near knee point of magnetization curve, however, adequate margin should be kept to take care for system conditions like overfluxing, frequency and voltage variations. In certain cases value of flux density is reduced to limit the noise level of transformers.

Influence of Varying Flux Density-Keeping the other parameters same, increase in the value of flux density in the core result in higher volts per turn. Hence numbers of turns in various windings are reduced. Effect of increase of flux density on reactance is similar to that of increase in core diameter. In order to meet the requirement of specified reactance, coil depth is reduced and lateral dimensions of coils are increased. In spite of small increase in core leg centres, reduced core height results in lower core-steel weight results in higher no-load loss of transformer. Also reduced number of turns in windings results in lower copper weight and load losses. Similarly, reduction in the value of flux density causes increased core-steel weight, lower no-load loss and increased copper weight and load loss.

SELECTION OF TYPE OF CORE-The cores are made of CRGO steel, which is available in various grades having different properties. Suitable grade of steel is chosen to suit the performance requirement and overall economy. Selection of type of core depends upon the rating of transformer and transport limitations. For large three-phase transformers, five-limb construction is adopted to overcome the problem associated with the transport height. For single-phase transformers, one centre-wound limb with two return limbs is a common configuration, though sometimes both limb wound cores are also adopted. For very large ratings, core construction having two wound limbs with two return limbs may also be adopted.

SELECTION OF LEG LENGTH- Maximum leg length available for designing the windings, is dependent upon maximum transport height, type of wagon to be used for transportation and type of core selected. By proper shaping of the transformer tank for well


wagon, the leg length can be increased. Generally for larger transformers maximum value of leg length gives the overall economy. Whereas, lower rating transformer may have reduced leg length to give economical design. By reducing leg length, reactance of transformer increases, and vice versa.

Influence of core diameter, flux density and leg length over various parameters while maintaining the % reactance as constant is tabulated below:





core diameter

flux density

leg length

Copper weight




Load loss




Core steel weight




No-load loss




SELECTION OF TYPE OF WINDINGS-The windings along with its insulations form the electric circuit of the transformer. Due care must be taken while designing the windings to ensure its healthiness during normal as well as fault conditions. The windings must be electrically and mechanically strong to withstand both over-voltage under incidence of surges and mechanical stresses during short-circuit conditions. The temperature of windings at rated, over-load and short-life of transformer.

SELECTION OF TAPCHANGER- To cater for the voltage regulation in the transformer and system voltage variation, off-circuit/on-load tapchanger is provided. Off-circuit tap switch is provided when tapchanging is required only occasionally. Generally generator transformers are provided with off-circuit tap switch. When tapchanging is required under loaded conditions, on-load tapchangers are provided. Generally, unit auxiliary transformers, station transformers, and system transformers are provided with on-load tapchangers. The choice of tapchangers is governed by the following factors:

Tapping range

number of steps

Step voltage

Current rating

Location of tapping

Design of tapping winding, i.e. linear, reversing, coarse and fine.

Insulation level

Type of voltage variation, i.e. constant flux, variable flux and mixed type.

Power flow requirement, i.e. unidirectional or bi-directional

CALCULATION OF NUMBER OF TURNS- It is done by using emf equation:

Volts per turn, E t =4.44B m where B m =Maximum flux density in tesla A=net cross-sectional area of core in m 2.


ƒ= frequency in Hertz













Transformer auxiliaries play a vital role in ensuring proper functioning of the main equipment. Some of the auxiliaries provide protection under fault conditions. Transformer oil being a major insulation requires special attention against contamination by moisture and oxygen for preservation of quality.


1. GAS OPERATED (BUCHHOLZ) RELAY The relay serves as main protection for any minor or major faults that may develop inside a transformer. Such faults always result in generation of gases which causes the operation of mercury switches giving signal for audible alarm or isolates the transformer from the network. It comprises a cast housing which contains two pivoted buckets, each bucket being counter- balanced by a weight. Each assembly carries a mercury switch, the leads from which are taken to a moulded terminal block. Operation- The relay is mounted in the pipe at an inclination of 3-7º as shown in Fig. 1 In healthy condition of the transformer, the relay is full of oil and both the mercury switches are open. In the event of a minor fault like damage to core bolt insulation, local overheating, etc. the arcing causes slow generation of gas in the oil, which passes up in the pipe and gets trapped in the relay housing. As the gas accumulates, the oil level in the relay falls, leaving the top bucket full of oil. When a sufficient volume of gas is collected in the relay, the top bucket, because of its extra weight due to oil contained, tilts, overcoming the balance weight which closes the mercury switch and initiates an audible alarm. With a major fault like short-circuit between turns, coils or between phases; the generation of gases is rapid and the gas and the displaced oil surges through the relay and impinges on the baffle plates, causing the lower assembly to tilt and close the mercury switch and provide signal for tripping the circuit breaker, which disconnects the transformer from the network.


Fig.16. Transformer auxiliaries 2. TEMPERATURE INDICATORS Temperature indicators are precision instruments, specially

Fig.16. Transformer auxiliaries


Temperature indicators are precision instruments, specially designed for protection of

transformers and perform the following functions.

Indicate maximum oil temperature and maximum or hottest spot temperature of winding.

Operate an alarm or a trip circuit at a predetermined temperature.

Switch on the cooling equipment when the winding attains a preset high temperature and switch it off when the temperature drops by an established differential (so as to avoid too frequent on and off operation of the switch).

Normally two separate instruments are used for indicating oil and winding temperatures.


The pressure relief valve plays a significant role in the protection of power transformer systems. As mentioned before, a major fault inside the transformer causes instantaneous vaporization of the oil, leading to extremely rapid build-up of gaseous pressure. If this pressure

is not relieved within a few milliseconds, the transformer tank can get ruptured, spilling oil over a wide area. The consequent damage and fire hazard possibilities are obvious. A pressure relief device provides instantaneous relieving of dangerous pressure.


Normally all transformers are provided with an expansion vessel called conservator, to take care of expansion in the oil volume due to rise in temperature, when the load on the transformer increases or due to increase in ambient temperature. The oil level in the conservator consequently goes up. Conversely, it falls when the temperature or load reduces. It is essential that the oil level in the conservator is maintained above a pre-determined minimum level. All large transformers are, therefore, fitted with a magnetic oil level gauge which also incorporates a mercury switch. The switch closes and actuates an audible alarm in the event of oil level dropping to near empty position in the conservator.



It is necessary to bring the low and high voltage leads out of transformer tank, to be able to

make connections between transformer and generator or transmission lines, etc. This is

accomplished by terminating these leads through what are known as bushings or cable box.

A bushing is a structure carrying a conductor through a partition in the tank and insulating the

conductor form partition.

Cable Sealing Box Generally used for termination of leads of low voltage, a cable sealing box is designed for the purpose of receiving and protecting the end of a metal-sheathed cable or cables and containing a suitable insulating medium.

It is a unit complete with bushings, to which the terminals of the transformer can be connected.

The insulating medium in a cable box can be air or a bituminous

The insulating medium in a cable box can be air or a bituminous compound. Fig.17. 400


Fig.17. 400 kV oil-impregnated paper bushing


Fig.18. Connections of bushings 6. TRANSFORMER OIL PRESERVATION SYSTEMS Transformer oil deterioration takes place due

Fig.18. Connections of bushings


Transformer oil deterioration takes place due to moisture. Moisture can appear in a transformer from three sources, viz. by leakage past gasket, by absorption from air in contact with the surface, or by its formation within the transformer as a product of deterioration as insulation ages at high temperature. The effect of moisture in oil is to reduce the electric strength, especially if loose fibres or duct particles are present. Methods available to reduce oil contamination from moisture are silicagel breather, thermosyphon filter, sealed conservator tanks using gas cushion, rubber diaphragm or air-cell sealed refrigerated dryers.

Silicagel Breather


silicagel breather is most commonly employed as a means of preventing moisture ingress. It


connected to the conservator tank, which is fitted to transformer to allow for changes in

volume due to temperature variations. As the load reduces, air is drawn into the conservator through a cartridge packed with silicagel desiccant, which effectively dries the air. Freshly regenerated gel is very efficient, it will dry the air down to a dew point of below- 40 ºC, but quickly falls in efficiency. A well maintained silicagel breather will generally operate with a

dew point of - 35ºC, as long as a large enough quantity of gel has been used for the cycling duty. Silicagel may be reactivated by heating in a shallow pan at a temperature of 150º to 200ºC for two to three hours when the crystal should have regained their blue tint.

RADIATORS AND FANS- They are used for cooling of the oil.


Fig.19. Radiator and fans MANUFACTURING AND ASSEMBLY Manufacturing and assembly of the transformer involves the

Fig.19. Radiator and fans


Manufacturing and assembly of the transformer involves the following main stages and the manufacturing techniques basically depend on the design philosophy.


Core building


Preparation of windings


Core and winding assembly


Terminal gear assembly


Placement of care and winding assembly in tanks.




Servicing and tanking

Core building

The sequence of operations for core building and assembly are as under:


Slitting of core steel rolls to required width on slitting machines.


Cropping and mitring to the required dimensions.


Hole punching in the laminations where required.


Stacking of laminations of different size to the required thickness.


Laying of clamp plates and end frame and its leavelling.


Assembly of insulation between clamp plate/end frame & core laminations.


Preparation of oil duct in core.


Core building.


Clamping of core after assembly of the top end frame.

(j) Tightening of core. (k) Lifting of core by use of a cradle, and carrying out isolation checks after treatment of insulation items. The core assembly is now ready for further processing and assembly.

Preparation of windings The sequence of manufacture of windings is given below:



Loading of moulds (formers) on the windings machines.


Loading of the conductor reels on stands.


Dressing of the mould, i.e. assembly of insulation spacers and blocks on the mould.


Manufacture of the winding on horizontal/vertical winding machines depending on design, type of winding, number of conductors, to be handled at a time and the type of conductor.


Preparation of the leads etc.


Dismantling of winding from the machine.


Preparation of the joints between conductors, if any.


After removing the winding from the winding machine, each winding is clamped between top and bottom plates through tie rods, and kept in an oven for heating. The windings are individually shrunk to the required axial dimensions by heating in the steam heated oven and by applying the required pressure. Heating ensures removal of moisture from the insulation items. This process is called stabilization of the windings, and the windings are stabilized to such an extent that they do not shrink further during service.

Core and winding assembly Core is placed on suitable levelled platform. Top-end frame and yoke laminations are removed. This process is known as unlacing of core. Bottom insulation items are placed on bottom yoke/end frame on each core leg. Various windings are either lowered one by one or composite winding assembly is lowered on each core leg. After lowering of the windings, top insulation arrangement is completed. Top-end frame and yoke laminations are placed back in position. This is known as relacing of core. Coils are kept under pressure by either coil clamping bolts or spring loaded hydraulic devices provided on the top-end frame.

Terminal gear assembly After relacing of the top yoke, the preparation of the Terminal Gear Assembly done as described below:


Cutting of the leads as required.


Crimping/brazing of the leads with cables.


Brazing of bus bars.


Fixing of different cleats.


Crimping/brazing of cables with terminal lugs.


Mounting of the tap changer/tap switch.


Preparation of HV line lead.

In this stage, connections between phases to form the required vector group, tapping lead connections, line and neutral leads formation, etc., are completed. Low-voltage connections are done on one side of the winding and are designated as LV terminal gear. On the opposite side, high-voltage connections are done and are designated as HV terminal gear. Medium voltage leads (in system or autotransformer are taken out on LV side and tapping connections on either LV or HV side depending upon design layout. Generally in generator transformer, a three-phase on-lad or off-circuit tap-changer is mounted on one end and in case of autotransformer three single-phase tapchangers are mounted in front of the windings. Tapchangers are supported from end frame during terminal gear assembly. All leads, i.e. line and neutral leads of low-voltage, medium-voltage and high-voltage windings, tapping leads, etc., are laid out and connected using different types of joints (i.e. bolted, crimped,


soldered or brazed) and insulated for the required insulation level. Leads are properly supported by cleast mounted on end frames. The clearances between various leads, coil to leads, leads to end frame and other parts are maintained and checked.

Placement of core and winding assembly in tank After completion of terminal gear assembly, the core and winding assembly is placed in the tank. The tank may either be of conventional or bell-shaped construction depending upon requirement. In case of bell-shaped construction the top part of tank and for conventional construction the bottom tank is prepared for this purpose. Preparations include mounting of shunts, barriers, etc., on tank walls as required and also laying of gaskets on the flange joints. In conventional tank, the core and winding assembly is lowered on the core and winding assembly. In bell-shaped tank construction, top tank is lowered on the core and winding assembly. After placement of core and winding assembly in tank, various electrical and mechanical clearances, viz. coils to tank, line, neutral and tapping leads to tank, etc., are checked. After the above checks are over, all the openings in tank and cover are blanked by blanking plates and gaskets. The transformer is then sent for drying and impregnation.

Processing The quality of a transformer and, consequently its performance and life depends essentially on the factory processing. The assembled active part of the transformer after tanking or before tanking as the case may be, is heated in an oven for extraction of moisture under vacuum. Sometimes, vacuum drying is done by drawing vacuum in its own tank and keeping the whole transformer in an oven. Besides the conventional method of drying, the most modern vapour proper dry out, as otherwise windings would become loose in service, and may get distorted under short circuit conditions. Once the moisture is extracted to the desired level, oil is filled under vacuum and the transformer is soaked in oil.

Servicing of transformer The transformer active part is then taken out and all the terminal gear clearing of the leads are retightened and the coils are clamped and secured in position. The transformer tank cover is then placed in its position and the transformer is now ready for further assembly of bushings etc.

Tanking After servicing the transformer is assembled with all the necessary fittings. The oil is filled under vacuum and it is circulated in order to get the desired ppm and BDV levels before being offered for final testing and subjected to high voltage testing.



In the construction of a transformer, the insulation system is the most important feature, and hence requires maximum attention. Normally, the oil, paper, and pressboard insulation has to be freed of dirt, dust, and moisture for obtaining the optimum insulation properties. Cellulose insulation used in power transformers has 8 to 10% of moisture by weight at ambient temperature, being a hygroscopic material. Water is injurious to transformer insulation system, since it reduces the electric strength and the resistivity of the oil and accelerates the deterioration of solid insulation. The final drying out is commenced either when the core and windings are placed in an autoclave or when they are fitted into their tank, all main connections made, and the tank placed in an oven and connected to the drying system. The tapping switch may be fitted at this stage, or later, depending on the ability of the tapping switch components to withstand the drying process.


Cellulosic insulation is dried by creating conditions in which water vapour pressure (WVP) around the insulation is less than that in the insulation. The vapour pressure in the insulation is increased by heating the insulation and the vapour pressure around the insulation is decreased by removing water vapour. Fig.3. shows pressure plotted against humidity and temperature, from which it is seen that a 20 ºC temperature rise increases the internal pressure by more than 100% (a factor of two). Basically one should aim at achieving the highest processing temperature consistent with the type and ageing properties of the insulation. The upper temperature limit is set by the maximum permissible drying temperature for paper, i.e. about 110 ºC (or 130 ºC in an oxygen-free atmosphere).

about 110 ºC (or 130 ºC in an oxygen-free atmosphere). Fig.23. Partial insulation water vapour pressure

Fig.23. Partial insulation water vapour pressure v. temperature, for various insulation moisture contents.

Drying efficiency also depends on diffusion coefficient of the insulation material. This coefficient is dependent on the material to be dried, its temperature, pressure and moisture content. Two basic processes are adopted for drying of transformers.



Conventional vacuum drying


Vapour phase drying


1. Drying Time

The drying time of the insulation increases considerably with the operating voltage and size of

the transformer. The longer the drying time, the higher is the partial discharge inception voltage. The time of drying depends on the final moisture content required in the insulation pressure rings, supporting components and pre-compressed press boards basically determine the minimum drying time.


The moisture content in cellulose insulation can be brought down to 2% from 8-10% by dry hot air circulation. For further reduction of moisture content, heating under vacuum is resorted to, so that the time required for drying can be reduced.

The core and windings assembly is placed in the clean transformer tank. Drying is carried out either in a vacuum vessel or in an air circulating drying oven. In the latter case, vacuum is drawn in the transformer tank.

Loading of Transformer

The tank containing core and windings is loaded into the vacuum vessel. For bell shaped tanks the openings on the top of the tank are kept open such that complete

cellulose insulation is oil impregnated subsequently. For drying in its own tank, the tank along with core and windings is loaded into the drying oven. Tank cover is placed in position and all openings are closed.

b. Vacuum Drying

The transformer is heated initially to 100ºC for about 24 hrs and a high vacuum in vessel or in its own tank is drawn. Higher the vacuum, better and quicker is the drying. Vacuum level to be achieved also depends upon voltage class of transformer. Vacuum corresponding to an absolute pressure as low as 1.33 Pa (0.01 torr) can be obtained. In order to maintain the transformer temperature at the required value, the pressure is increased to atmospheric level by the admission of hot dry air at intervals during the first few days of drying. This is necessary since winding temperature drops considerably as latent heat of transformer is utilized in conversion of insulation moisture into water

vapours. During vacuum drying, the quantity of water collected at pump is recorded at regular intervals. Insulation resistance, power factor and dispersion factor of windings are also monitored. Vacuum drying is considered to be complete, when desired condensate extraction rate is achieved and other parameters indicated above become reasonably steady.

c. Reconditioning of Insulating oil

There is a tendency for oil to absorb water due to breathing during transport and storage. Impurities, by the solid ones like hygroscopic fibres, suspended particles or liquid ones like dissolved water, bring about a considerable reduction of the dielectric strength of oil.


Oil at 20 ºC saturated with water (44 ppm) attains only about 25% of the original electric strength with a water content of 10 ppm. Under the same conditions, the resistivity of oil also drops considerably. Air, especially oxygen, dissolved in the oil represents a risk not only with regard to the formation of bubbles but also due to accelerated oxidation process leading the chemical deterioration of oil. Hence, it is necessary to treat and purify the oil before impregnating the windings, so as to attain a degree of purity which meets the operational requirements. Oil is reconditioned to eliminate the following elements.


Solid impurities


Free and dissolved water


Dissolved gases

The physical means that are used for treatment of oil include several types of filtration,

centrifuging and vacuum dehydration techniques. If vacuum treatment is employed,

temperatures up to 80 ºC can be used; if not, it is advisable to limit the temperature of oil

to 60 ºC to prevent oxidation. The filters used should be capable of removing particles

larger than one micron diameter. Along with drying of transformer, raw oil is reconditioned in a vacuum dehydrator, till

desired characteristics are obtained.

d. Oil Impregnation

After completion of vacuum drying, the reconditioned oil is admitted to the transformer without breaking vacuum in the vessel or tank, as the case may be. The transformer is allowed to cool to a temperature of about 70 ºC before filling with oil. Temperature of reconditioned oil is maintained at 50 + 10 ºC. Care is taken to ensure that pressure in vessel or tank is not too low to vaporize the oil. The oil flow rate normally does not exceed 3 kl/h so that all residual gases occluded in crevices among insulation items are released and the possibility of gas bubbles being trapped at any place inside tank is prevented. Oil is filled until all cellulose insulation is covered.

e. Re-drying and Oil Circulation

Oil impregnated transformer is kept under vacuum for a few hours so that solid insulation

is completely soaked with oil. Winding insulation shrinks to some extent during drying as

the initial water in cellulose is extracted. Hence, windings and cleats of terminal gear are retightened after taking the assembly out of tank.

A little moisture reabsorbed by the insulation due to exposure to atmosphere during this

period is extracted by re-drying under vacuum and subsequently oil is again impregnated inside the transformer. Oil is circulated to regain its electric strength and moisture content which deteriorate due to contact with materials used in the construction of transformer. Solid particles, fibres of different origins and all other impurities are separated at filter. A settling time is given before conducting high voltage dielectric tests on the transformer, so that suspended fine particles are settled and occluded gas is fully released.

3. VAPOUR PHASE DRYING The main difference between conventional vacuum drying and vapour phase drying is that, in the latter process the heat carrier is a vapour of low viscosity solvent, more like kerosene with a sufficiently high flash point instead of air. The vapour is condensed on the transformer and then re-evaporated in the plant. For this reason, vapour phase installation include an evaporator and


condenser system in addition to the vacuum equipment and vacuum vessels associated with conventional drying equipment.


Testing is an important activity in the manufacture of any equipment. While certain preliminary tests carried out at different stages of manufacture provide an effective tool which assures quality and conformation to design calculations, the final tests on fully assembled equipment guarantee the suitability of the equipment for satisfactory performance in service. The basic testing requirements and testing codes are set out in the national and international standards. Transformers can be subjected to a wide variety of tests for a number of reasons, including:

• Compliance with user specifications

• Assessment of quality and reliability

• Verification of design calculations

• Compliance with applicable industry standards

Preliminary tests are carried out on the transformer before it is put into the tank. Final tests are carried out on completely assembled transformer.

1. Preliminary Tests Following tests are carried out in the works at different stages, before the core and coil assembly of the transformer is placed in its tank. These checks help in detecting any fault at an early stage.

(a) Core Insulation

After the core is assembled, 2 kV test is done to ensure that the insulation between clamp

plates, core bolts and core is adequate.

(b) Core loss Test

This is conducted in the core assembly to ensure its soundness. Some turns are wound over the core and it is energized at normal flux density. Coreloss and magnetizing current are noted and

compared with design value.

(c) Check of Ratio, Polarity, Vector Relationship and Winding Resistance of Transformer

Assembly Ratio test is conducted to ensure the correctness of voltage ratio between different windings on each tapping. The tolerance allowed for ratio is + 0.5% of the declared ratio or + 10% of the percentage impedance voltage, whichever is smaller. The latter tolerance limit is not applicable for auto-transformers and booster transformers, where impedance value is small. In order to get accurate ratio, a ratiometer is employed. It also indicates the polarity of transformer windings.


For a three-phase transformer, it is more usual to carry out a vector relationship test, in which one of the high-voltage and low-voltage line terminals are jointed together as shown in Fig. 1. Three-phase 400 V supply is connected across high voltage line terminals.

V supply is connected across high voltage line terminals. Fig.24. Vector relationship test for star-delta (YN,

Fig.24. Vector relationship test for star-delta (YN, d11) connected Step-down transformer.

Voltages between terminals 2U1N, 2V1N, 1U1N, 2V1V, 2W1W and 2V1W are measured. For YN, d11 vector relationship


2V1W>2V1V or 2W1W The vector relationship for any other group can be checked in a similar manner. The dc resistance of each winding is measured by Kelvin’s double bridge to check that there is no faulty joint.

(d) Preliminary Load Loss and Impedance Voltage Measurement

Preliminary load loss and impedance measurements at reduced current are carried out to ensure

that these are within guaranteed limits.

2. Final Tests The completely assembled transformer is tested in accordance with the International Standards. The tests comprise the following:

(a) Routine tests

(i) Measurement of winding resistance- The DC resistances of both HV and LV windings can be measured simply by the voltmeter/ammeter method, and this information provides the data necessary to permit the separation of I2R and eddy-current losses in the windings.

(ii) Measurement of voltage ratio and check of voltage vector relationship- Measurements are made on every transformer to ensure that the turn ratio of the windings, tapping positions and winding connections is correct. The tolerance as per relevant standard at no-load on the principal tapping is ±0.5% of the declared ratio. These measurements are usually carried out during assembly of both the core and windings, while all the connections are accessible, and finally when the transformer is fully assembled with terminals and tap changing mechanism.

(iii) Measurement of impedance voltage (principal tapping) short circuit impedance and load loss


(iv) Measurement of no load loss and current- The no-load loss and the no-load current shall be measured on one of the windings at rated frequency and at a voltage corresponding to rated voltage if the test is performed on the principal tapping, or to the appropriate tapping voltage if the test is performed on another tapping. The remaining winding or windings shall be left open- circuited and any windings which can be connected in open delta shall have the delta closed.

(v) Measurement of insulation resistance- Insulation resistance tests are carried out on all windings, core and core clamping bolts. The standard Megger testing equipment is used, the ‘line’ terminal of which is connected to the winding or core bolt under test. When making the test on the windings, so long as the phases are connected, together, either by the neutral lead in the case of the star connection or the interphase connections in the case of the delta, it is only necessary to make one connection between the Megger and the windings.

(vi) Dielectric tests- The insulation of the HV and LV windings of all transformers is tested

before leaving the factory. These tests consist of:


separate-source voltage withstand test


Induced over voltage withstand test

a) Separate source AC voltage:

This test is intended to check the adequacy of main insulation to earth and between windings. The line terminals of the windings under test are connected together & the appropriate test voltage is applied to them, while the windings & tank are connected together to the earth. Winding with graded insulation, which have neutral intended for direct earthing, are tested at 38 kV. The supply voltage should be nearly sinusoidal and the peak voltage is measured from digital peak voltmeter associated with capacitive voltage divider. The duration of test is 60 seconds.

b) Induce over voltage withstand test:

The test is intended to check the inter-turn and line end insulation as well as main insulation to earth & between windings.

In order to avoid core saturation at the test voltage, it is necessary to use a supply frequency higher than the normal. When frequency is chosen in the range of 100-200 Hz, capacitive reactance is reduced, and in draws significant capacitive current at test voltage, which causes heavy loading on the generator can be reduced by connecting a variable reactor across the generator terminals.

Test duration is determined by the following formula-

Test duration in seconds= but not less than 30 sec.

The test is applied to all the non-uniformly insulated windings of the transformer. The neutral terminal of the winding under test is earthed. For other separate windings, if they are star connected they are earthed at the neutral and if they are delta connected they are earthed at one of the terminals.



Tests on-load tap changers (where appropriate)

(b) Type tests

Type tests are tests made on a transformer which is representative of other transformers to

demonstrate that they comply with specified requirements not covered by routine tests.

1. Temperature rise test.

2. Noise level test.

(c) Special tests

Special tests are tests, other than routine or type tests, agreed between manufacturer and

purchaser, for example:

(i) Dielectric special tests.

(ii) Measurement of zero-sequence impedance of three-phase transformers


Short-circuit test


Measurement of acoustic noise level


Measurement of harmonics of the no load current


Measurement of power taken by the fans and oil pumps


Measurement of capacitances between windings to earth and between windings.

(viii) Measurement of transferred surge voltage on low voltage windings.

(ix) Measurement of insulation resistance to earth of the windings, or measurement of dissipation factor (tan delta) of the insulation system capacitances.

dissipation factor (tan delta) of the insulation system capacitances. Fig.25. Impulse Voltage Generator Fig.26. Shooter 66

Fig.25. Impulse Voltage Generator

dissipation factor (tan delta) of the insulation system capacitances. Fig.25. Impulse Voltage Generator Fig.26. Shooter 66

Fig.26. Shooter



The power transformer is the most important component of the power transmission and distribution. A transformer works on the principles of induction which states that only the current and voltages shall be transformed and energy will only get ‘transferred’. BHEL is a leading Engineering Enterprise which Supplies wide Spectrum of Power Transformers. These transformers undergo several stages of manufacturing process and at the end of every process various tests like type tests, routine tests etc. are performed on them to ensure its status during manufacture and a reliable operation after manufacturing.

These four weeks helped me a lot in gaining the knowledge on power transformers. It made me aware of various stages of transformer manufacturing processes and different tests that are conducted on them.



[2] “Transformers” by Bharat Heavy Electricals Limited.

[3] TCB learning module.

[4] The J&P Transformer Book by Johnson & Phillips Ltd.

[5] “Electrical Machines” by P.S. Bhimbhra.