TRANSFORMER

A transformer is a static machine used for transforming power from one circuit to another
without changing frequency. This is very basic definition of transformer. Transformer
generally
used in transmission network is normally known as Power Transformer. 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.

HISTORY:
The History of transformer commenced in the year of 1880. In the year of 1950 400KV
electrical power transformer first introduced in high voltage electrical power system. In the
early 1970’s unit rating as large as 1100MVA were produced and 800KV and even higher
KV class transformers were manufactured in year of 1980.

WORKING PRINCIPLE:
The working principle of transformer is very simple. It depends upon Faraday's law of
electromagnetic induction Actually mutual induction between two or more winding is
responsible for transformation action in an electrical transformer.
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.
𝒅𝒊
e=𝑴 𝒅𝒕
where, e = induced emf M = mutual inductance
If the second circuit is closed, a current flow in it and so electric energy is transferred
(entirely magnetically) from the first coil (primary winding) to the second coil (secondary
winding).

FIG:1.1 MUTUAL INDUCTION IN TRANSFORMER

MAIN CONSTRUCTIONAL PARTS:

1. Primary Winding of transformer - which produces magnetic flux when it is connected to
electrical source.
2. Magnetic Core of transformer - the magnetic flux produced by the primary winding, will
pass through this low reluctance path linked with secondary winding and creates a closed
magnetic circuit.
3. Secondary Winding of transformer - the flux, produced by primary winding, passes
through the core, will link with the secondary winding. This winding is also wound on the
same core and gives the desired output of the transformer.

FIG:1.2 TRANSFORMER CIRCUIT

 1.POWER TRANSFORMER
The Power transformer is a one kind of transformer, that is used to transfer electrical
energy in any part of the electrical or electronic circuit between the generator and the
distribution primary circuits. These transformers are used in distribution systems to interface
step up and step down voltages. The common type of power transformer is liquid immersed
and the life span of these transformers is around 30 years.
Power transformers can be classified into three types based on the ranges. They are
1.small power transformers.
2.medium power transformers.
3. large power transformers.

 The range of small power transformers can be from 500-7500kVA

 The range of medium power transformers can be from -100MVA
 The range of large power transformers can be from 100MVA & beyond

FIG:2.1 POWER TRANSFORMER

BHEL Jhansi unit manufacture power transformer up to rating 400KV/315KVA
1.1 STAGES OF POWER TRANSFORMER MANUFACTURING
1. CORE BUILDING
2. UNLACING OF CORE
3. CORE COIL ASSEMBLY AS PER DRAWING /ELECTRICAL SPECIFICATION
4. FIRST PROCESS-VAPOUR PHASE (for achieving relacing level)
5. RELACING OF CORE
6. TERMINAL GEAR MOUNTING
7. SECOND PROCESS VAPOUR PHASE AND OIL IMPREGNATION
8. SERVICING
9. TANKING
10.CONVENTIONAL (Heating/Vaccum) AND OIL FILLING UNDER VACCUM
11. CASE FITTING
12. FINAL TESTING
(testing after stages 1,4,5,6,8)

1.2 CONSTRUCTION
a. Core building
The base is made up of frames on which core is mounted as shown in figure. The top and end
frame and bottom end frame are connected.

FIG:2.3 core Layout

Core building done on three 65T cradle, which ensures minimum jerk during lifting of core.
Construction in which the iron circuit is surrounded by windings and forms a low reluctance
path for the magnetic flux set up by the voltages impressed on the primary.
The steel strip surface is subjected to inorganic insulation treatment. All cores employ meter-
joint core construction. Yokes are jointed at an angle of 45° to utilize the magnetic flux
directional characteristic of steel strip.
When erecting a core after assembling, a special device is used so that no strain due to
bending or slip is produced on the silicon steel.
The sequence of operations for core building and assembly are as under:
(a) Slitting of core steel rolls to required width on slitting machines.
(b) Cropping and mitring to the required dimensions.
(c) Hole punching in the laminations where required.
(d) Stacking of laminations of different size to the required thickness.
(e)Laying of clamp plates and end frame and its levelling.
(f) Assembly of insulation between clamp plate/end frame & core laminations.
(g) Preparation of oil duct in core.
(h) Core building.
(i) 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.

FIG:2.4 CORE ASSEMBLY

b. Preparation of windings
The sequence of manufacture of windings is given below:
(a) Loading of moulds (formers) on the winding machines.
(b) Loading of the conductor reels on stands.
(c) Dressing of the mould, i.e. assembly of insulation spacers and blocks on the mould.
(d) 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.
(e) Preparation of the leads etc.
(f) Dismantling of winding from the machine.
(g) Preparation of the joints between conductors, if any.
(h) 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.

FIG:2.5 WINDIND ASSEMBLY

c. 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.

FIG:2.6 CORE AND WINDING ASSEMBLY

d. Terminal gear assembly
After relacing of the top yoke, the preparation of the Terminal Gear Assembly
done as described below:
(a) Cutting of the leads as required.
(b) Crimping/brazing of the leads with cables.
(c) Brazing of bus bars.
(d) Fixing of different cleats.
(e) Crimping/brazing of cables with terminal lugs.
(f) Mounting of the tap changer/tap switch.
(g) 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 auto transformer 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 auto transformer three single-phase tap changers are mounted in
front of the windings. Tap changers 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 c least mounted on end frames.
The clearances between various leads, coil to leads, leads to end frame and other parts are
maintained and checked.

FIG:2.7 TERMINAL BEAR ASSEMBLY

 FIG:2.8 TRANSFORMER ASSEMBLY WITH OLTC

e. 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.

f. 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.The paper insulation and pressboard material, which make up a significant
proportion by volume of transformer windings, have the capacity to absorb large amounts of
moisture from the atmosphere. The presence of this moisture brings about a reduction in the
di-electric strength of the material and also an increase in its volume.
The final drying out is commenced either when the core and windings are placed or when
they are fitted into 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 switch components to withstand the drying process.
Once the moisture is extracted to the desired level, oil is filled under vacuum and the
transformer is soaked in oil.
g. 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.
h. Tanking
The transformer tank provides the containment of the core and windings and for the dielectric
fluid. It must withstand the forces imposed on it during transport.
Transformer tanks are almost invariably constructed of welded boiler plate to BS 4630. The
tank must have aremoval cover so that access can be obtained for the installation and future
removal. The cover is fastened by a flange around the tank. The cover is normally inclined to
the horizontal at about 1°, so that it will not collect the rain water.
The job is finally put into a tank in which various points are taken care of such as:
 The proper tank dimensions is achieved as specified in the design.
 Weld leakagetest is performed on the tank to check that whether any kind of leakage is
present in the tank or not.
 Vacuum and pressure test is performed on the tank to check its endurance.
The accessories are fixed and final touches given to job. The accessories include tank cover,
fixing bushing, fixing valves etc. The terminal are marked R&D (rating and drawing) plate is
fixed by bolting.

FIG:2.9 transformer tank

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.

FIG:2.10 Complete transformer

After successful completion of testing, transformer is handed over to dispatch sections. At this
stage after checking oil leakage, dismantling of all bushings, turrets etc. and covered with the
blanking plates and the tank is fitted with nitrogen gas and then the transformer is dispatched
to the concerned site.
DRYING AND IMPREGNATION

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.
TESTING OF TRANSFORMERS

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.
FIG:2.11 IMPULSE VOLTAGE GENERATOR FIG:2.12 SHOOTER

2.Cast-resin dry-type transformer

The BHEL make cast resin dry type transformer consist of high voltage and low voltage
winding made up of copper conductors which are completely encapsulated and cast under
vacuum. The casting is done using liquid epoxy resin, reinforced by fibre glass insulation of
class F to form a very robust and maintenance free insulation system for winding. The H.V.
and L.V. coils are cast separately to form individual solid cylinder. The ore is made up from
lamination of rolled grain oriented low loss non-aging silicon steel. The core edges are coated
with special resin as a protection against rusting. The transformer is provided with suitable
protective steel enclosures. The enclosures are provided with suitable protective steel
enclosures. The enclosures are provided with wire mesh to provided free circulation of clean
natural air inside the enclosures for AN (Air Natural) cooling. For thermal protection, RTD
PT- 100 sensors embedded in the coil to do the temperature monitoring of transformer. These
sensors feed signals to temperature scanner for continuous monitoring of winding temperature
scanner unit for continuous monitoring of winding temperature.
The temperature scanning unit is provided unit is provided with auxiliary relays, one for the
alarm and for trip. Alarm relays should be wired with suitably located alarm to give an
indication if the transformer winding temperature is exceeded. The trip relay should be wired
with the HT circuit breaker to trip the supply in case temperature rises beyond the safe limit
because of any fault whish may damage the transformer permanently. The control wiring is
terminated on the terminals blocks located inside the junction box on the enclosure. In addition,
the enclosure is provided with suitable earthing pads for earthing.

FIG:3.1 CAST RESIN DRY TYPE TRANSFORMER

BHEL Jhansi unit manufacture dry type transformer up to rating 33KV/3150KVA

MANUFACTURING PROCESS OF DRY TYPE CAST RESIN

TRANSFORMER
The dry type cast resin transformer is manufactured using copper conductors for winding and
epoxy resin for insulation. The process is as follow:

a. WINDING
Winding of copper conductors make both L.V. and H.V. windings over steel formers. The
winding is densely embedded in glass fibres and held tightly by glass tapes. L.V. windings
are generally helical in shape and H.V. windings are generally made spiral or disc type. Both
the windings are made separately except for very small rating where H.V. and L.V. are made
together because of small diameter. After winding is complete the wound coils are placed in
separates steel moulds and pre-dried is heating oven or heated vacuum chamber before
casting.
b. MOULDING
Dried moulds containing the windings are placed in vacuum chamber for casting. Casting is
done by utilizing properties offered by pure liquid epoxy system. Various constituents of
liquid epoxy resins are first heated in separate vacuum pots to eliminate dissolved gases and
moisture. Then these are mixed in precise proportion as per the requirements and supplied to
dried winding placed inside the moulds under high vacuum to give void less embedment of
winding by epoxy. The epoxy reinforced by glass after curing forms a solid mass, which
encapsulates and hermetically seals the copper winding. The process gives the winding better
mechanical strength than any other known form of manufacturing process at the same time
epoxy system employed provided a high dielectric strength.

c. CUTTING AND DRESSING

After the coils are cured they are taken out of the moulds. The cured and dried coils are hard
enough to carry out marching. Rather the hardness of fibre glass reinforced epoxy resin cast
cols requires tools and blades machining as ordinary steels tools for cutting steels and other
metals wears out quickly. Excess epoxy deposited on the top of cols is sawn off required
dimensions and sharp edges are removed and smoothened by milling or grinding. Touching
up paints is applied to coils if required and finished coils are tested and sent to assembly.

d. ASSEMBLY OF TRANSFORMER
The finished cast resin coils are placed in core by removing the top yoke of preassembled
core. The top yoke is replaced after placing H.V. and L.V. coils. The coils are supported at
top and bottom by end blocks. The core and winding are then clamped tightly together by
galvanized steel channels and terminals gear assembly is carried out for the required H.V. and
L.V. terminations. Specials class F resin is applied on the exposed area of core as a protection
against rusting. The core and coils assembly are then mounted on the roller base. After fixing
bi-directional, rollers enclosure is bolted to core and coil assembly.

1. Low Voltage Connections (LV)

2. Lifting Eyebolts
3. Rating Plate
4. Magnetic core
5. High voltage (HV) winding
6. Earth terminals
7. Truck with oriented rollers
8. Tapping’s for voltage settings
9. Medium Voltage Connections (HV)
10. Terminal box for temperature probes
11. Delta Connection
12. Towing points for horizontal
movement
13. Temperature probes
APPLICATIONS
Cast resin transformers can be used in a wide range of applications and represent the most
reliable answer for distribution systems, power production, rectification, traction and for
special solutions.
SERVICE SECTOR
Hospitals
Hotels
Banks
Schools
Shopping and cultural centres
Management centres

INFRASTRUCTURES
Airports
Military installations
Ports
Off-shore installations

INDUSTRY
Automotive technology
Mechanical industries
Chemical industries
Paper mills
Foundries
3.Rectifier Transformers – Operation and Application
Rectifier transformers are different from normal power and distribution transformers because
they are special transformers made for industrial application. A Rectifier transformer is a
special application transformer which includes diodes and thyristors in the same tank.
Power electronic circuits can convert alternating current (ac) to direct current (dc). These are
called rectifier circuits. Power electronic circuits can also convert direct current to alternating
current. These are called inverter circuits. Both of these circuits are considered to be converters.
A transformer that has one of its windings connected to one of these circuits, as a dedicated
transformer, is a rectifier transformer or converter transformer.
Some other special industrial purpose transformers are Electric arc furnace transformers (EAF),
DC electric arc furnace transformers (DC EAF),Rectifier transformers, Converter transformers,
Line Feeders.
Rectifier transformers are used for industrial processes which require a significant direct
current (dc) supply. Rectifier circuits are used to provide high-current dc for electrochemical
processes like chlorine production as well as copper and aluminium production.
They are also used in variable-speed-drive motor controls, transit traction applications, mining
applications, electric furnace applications, higher-voltage laboratory-type experiments, high-
voltage direct-current power transmission (HVDC), static precipitators, and others.

Operation of Rectifier Transformers

Rectifier transformers can be liquid-immersed, dry-type, or cast-coil technology. Dry type
transformers were primarily used in distribution-voltage classes. Dry type and cast coil — are
limited by voltage and kVA size. However, liquid-immersed transformers can be built to all
voltage levels and current levels. High-fire-point fluids can be used for fire-protection
considerations.
Voltage regulation is achieved with no-load or on-load tap changers on the high voltage side.
Fine levels of voltage regulation can be achieved using saturable reactors on the secondary
side. Regulation units may be built in or separate.

Working Principle Of A Rectifier Transformer

Transformers are the basic need of all the industries involved in heavy generation and usage of
electricity transmission.
A transformer made with the diodes or thyristors in the same tank is installed for the voltage
regulation. It is designed to fight back the issues of eddy current and harmonics. Achieving
fine levels of the voltage regulation is possible with the device called rectifier transformer
where regulation units may be built within or separately.
APPLICATIONS
The device is suitable for the heavy voltage applications. A number of applications demand
special industrial transformer, as the prevailing devices are unable to bear the load of such
applications. It provides necessary supply of power to the low voltage supply without causing
any problem or destruction. They are used in different applications like Mining, Electrical
Furnace, Laboratory Experiments, Variable Speed Drive Motor Control, etc.

4.INSTRUMENT TRANSFORMER
In power system, the currents and voltages are very large. It might appear that the extension
of range could be conveniently done by the use of shunts for currents and multiplier for
voltage measurement, as in DC. The solution is to step The solution is to step -down these
currents/voltages with the down these currents/voltages with the help of Instrument
Transformer
Instrument transformers are other type of transformers which is mainly use for
measuring purposes. To Measure high voltages and high currents these kind of
instrument transformers are widely used. Ammeters and Voltmeters are use for
measure the voltage and currents of Direct Current but in High voltage alternative
Current instruments are difficult to measure by using ammeters a nd voltmeters. So to
solve these problems instrument transformers are use to measure these kinds of large
alternative currents and voltages. Normally Instrument Transformers can divide in to
two sections such as Current Transformers and Potential Transfor mers.

FIG:5.1 INSTRUMENT TRANSFORMER

1.CURRENT TRANSFORMER
Current transformer is used to step down the current of power system to a lower level to
make it feasible to be measured by small rating Ammeter (i.e. 5A ammeter). It is a type of
current transducer that will give current in the secondary which is proportional in magnitude
to the current flowing through the primary. These are used to convert the high currents from
power circuit into a measurable current range of instruments and control devices. In addition,
they provide isolation to the ammeters, other measuring instruments and control devices from
high voltage power circuitry. It is the cheapest and easiest method of current measurement
above the range of digital meters and moving coil vane meters. A typical connection diagram of
a current transformer is shown in figure below

Primary of C.T. is having very few turns. Sometimes bar primary is also used. Primary is
connected in series with the power circuit. Therefore, sometimes it also called series
transformer. The secondary is having large no. of turns. Secondary is connected directly to an
ammeter. As the ammeter is having very small resistance. Hence, the secondary of current
transformer operates almost in short circuited condition. One terminal of secondary is earthed
to avoid the large voltage on secondary with respect to earth. Which in turns reduce the chances
of insulation breakdown and also protect the operator against high voltage. More ever before
disconnecting the ammeter, secondary is short circuited through a switch ‘S’ as shown in figure
above to avoid the high voltage build up across the secondary.

FIG:5.2 CURRENT TRANSFORMER

CONSTRUCTION
The construction of the current transformer can be wound or bar type. Wound type CT is
similar to the two winding conventional transformer. The primary winding consists of more
than one full turn or multiple turns which is wounded on the core. For a low voltage wound
type CT, the secondary turns are wound on a Bakelite former and with a suitable insulation in
between, primary are directly wounded on the top of the secondary winding. Depends on the
core structure, these can be ring, or rectangular or window type CTs. In bar type CT, the
primary winding is nothing but a single bar which passes through the centre of the core forms
single turn primary winding.

The flux densities used in CTs are much less compared to the power transformers. Therefore,
core materials are selected such that they ensure low reluctance, low core loss and also to
work with low densities of flux. Since the ring cores are of joint less and robust, hence they
offer low reluctance. Common materials used for the cores include hot rolled silicon steel,
cold rolled grain oriented silicon steel, and nickel iron alloys. For high accuracy metering,
core of the CT is made with very high grade alloy steel called as Mu meal. To provide
insulation, varnish and tape materials are used for small line voltages. But for high line
voltages, compound filled or oil filled CTs are used. In case of CTs used in higher
transmission voltages, insulation between secondary windings and HV conductors uses oil-
impregnated paper. Again the construction of such CTs can be live tank and dead tank forms.
Types of current Transformer
The current transformer is mainly classified into three types, i.e., wound current transformer,
toroidal current transformer and bar-type transformers.

1. Wound Transformer – In this transformer the primary winding is composed inside the
transformer. The primary winding had a single turn and connected in series with the
conductor that measured the current. The wound transformer is mainly used for measuring
the current from 1amps to 100 amps.

2. Bar-type Current Transformer – The bar type transformer has only secondary windings.
The conductor on which the transformer is mounted will act as primary windings of the
current transformers. The insulation on the primary may be bakelite tube or the paper
wrapped directly on the bar.

3.Window Current Transformer – This transformer does not contain primary windings.
The line through which the current flow in the network is attached through a hole or a
window of the transformers. The major advantage of this transformer is that the transformer
has a symmetrical shape due to which it has a low leakage flux, thus less electromagnetic
interference

Applications of Current Transformers

The current transformers are used in a wide variety of applications ranging from power
system control to the precise current measurement in industrial, medical, automotive and
telecommunication systems. Some of the applications include
  Extending the range of measuring instruments such as ammeter, energy meter, KVA
meters, wattmeter, etc.
 Differential circulating current protection systems.
 Distance protection in power transmission systems.
 Over current fault protection.

2.VOLTAGE TRANSFORMER
The potential transformer may be defined as an instrument transformer used for the
transformation of voltage from a higher value to the lower value. This transformer step down
the voltage to a safe limit value which can be easily measured by the ordinary low voltage
instrument like a voltmeter, wattmeter and watt-hour meters, etc.

CONSTRUCTION
Voltage transformer mainly consist of:
1.Primary and Secondary winding
2.Electromagnetic Core

3.Bottom Tank and Oil Expansion Chamber

4.Porcelain Bushing

PRIMARY AND SECONDARY WINDING

Copper enamelled wire is used for winding. Primary is wound with multilayer and
graded insulation. The diameter and length of each layer is selected such that the
surge voltage is distributed equally in all layer of the winding. Multilayer craft paper
insulation is provided between winding layers. Stress equalising shield is provided on
last layer of the winding. H.T. connection is brought out through mettalic pipe.
Secondary is separately wound and inserted in the primary winding as per the
requirement. Winding and tapping of V.T.is done in dust free atmosphere.
ELECTROMAGNETIC CORE
C.R.G.O Silicon Steel is used for building up magnetic core. Shell type construction is
used to minimise leakage reactance.
BOTTOM TANK AND OIL EXPANSION CHAMBER
Bottom tank and oil expansion chamber are made of M.S. sheet. All tanks and
chambers are painted with oven baked paint, after cleaning by seven tank process. All
surface which come in contact with oil are painted with oil insoluble paint. M.S. parts
can be hot dip galvanised on request.
PORCELAIN BUSHING
Brown Glazed Porcelain bushing with different shed profile to suit different pollution
condition are used. These bushing are hollow cylindrical type. Bushing with collar at
both the ends is clamed using Aluminium flanges. Nitrile and Neoprene gaskets are
used at both side of collar to form a flexible joint. The joint can sustain vibrations
without damping bushing. Bushing with cemented flanges are also used.

FIG:5.3 VOLTAGE TRANSFORMER

Applications of Voltage Transformer

It is used for a metering purpose.
For the protection of the feeders.
For protecting the impedance of the generators.
For synchronising the generators and feeders.
The potential transformers are used in the protecting relaying scheme because the potential
coils of the protective device are not directly connected to the system in case of the high
voltage. Therefore, it is necessary to step down the voltage and also to insulate the protective
equipment from the primary circuit.
5.ELECTROSTATIC PRECIPITATOR
Electrostatic Precipitator can be defined as a type of air cleaner or filter that utilizes electric
energy for removing the impurities, dust particles from the air. This is a commonly used device
for controlling air pollution. Most of the industries, power stations generate fossil fuels in the
process of electricity generation or manufacturing process.

When these fuels burn, then the smoke will generate which includes the small soot particles
that are balanced the air. The carbon particles which are not burned can pull out from the smoke
with the help of electrical energy in the precipitator. It is essential for removing carbon particles
from the burn because it can harm human health as well as properties like buildings.

ELECTROSTATIC PRECIPITATOR CONSTRUCTION

This device includes two sets of electrodes namely positive as well as negative. The appearance
of the positive electrodes is like plates whereas the negative electrodes are in the shape of a
wire mesh or rod. These two electrodes are arranged vertically one after another in the
precipitator. The connection of the two electrodes can be done by connecting the positive and
negative electrodes to the two terminals of the DC source. The DC source positive terminal
may be connected to GND for getting strong negativity to the negative terminals. The distance
between the two electrodes and applied DC voltage are corrected.
The components of electrostatic precipitator include Electrodes, 3 phase supply 50 Hz 440v,
control cabinet, High voltage transformer, Rectifier, Hooper and Insulators.
 The control cabinet is applicable for interconnecting the transformer & 3 phase ac supply
using wires.
 The function of a transformer in an electrostatic precipitator is for step-up & step-down the
voltage.
 The main function of a rectifier in an electrostatic precipitator is to alter the AC supply into
DC supply.
 The hooper is useful for storing the particles of dust & content of ash from the electrostatic
precipitator.

Electrostatic Precipitator Working

The electrostatic precipitator working principle is very simple. The unclean flue gas flowing
through the tube is supplied by two electrodes. The shape of the two electrodes mainly depends
on the type of precipitator employed like bars, plates, metal wires, etc.
One of the plates is charged by a high negative voltage, which causes particulates in the burn
for getting a negative charge because they flow with this plate. The next plate carries a high
positive voltage equally, due to the fact that opposed charges attract. The soot elements which
are negatively charged are pulled in the direction of the positive electrode & fix to it. Irregularly
these two plates should be cleaned for eliminating the collected dust. Most of the electrostatic
precipitator’s works in the same method, and there are several dissimilarities as well as types
that work well for different amounts of pollution, shaped particles, and smoke compositions.
Advantages of Electrostatic Precipitator
The advantages of electrostatic precipitator include the following.

 The elimination of high-efficiency pollutants (or) particles

 Collection of dry & wet impurities
 Operating cost is low.
Disadvantages of Electrostatic Precipitator
The disadvantages of electrostatic precipitator include the following.

 Very expensive
 It requires huge space
 It is not supple once fixed
 They are not useful in collecting the gaseous pollutants
Electrostatic Precipitator Applications
The applications of electrostatic precipitator include the following.

 The most common application of Electrostatic precipitator is an industrial application for a

smoke. It looks like a gas; however, it is basically an accumulation of hard elements floating
in the atmosphere. These elements can be excited, letting them be composed of enormous,
commercial precipitators.
 The dry electrostatic precipitators are used for collecting dry particles like cement, ash, etc.
 The wet electrostatic precipitators are used for removing the wet particles like oil, tar, resin,
acid, etc.
 Electrostatic Precipitators are used in steam plants for removing the dust from flue gases.
 Electrostatic Precipitators are used in machine shops and chemical plants for removing oil
mists and acid mists.
 These are used to clean the blast or metallurgical heating system gases
 ESPs are used to remove the bacteria & fungus in the medical field.
 ESPs are used in air conditioning systems for sanitizing air
 ESPs are used to recover the materials in the flow of gas
 ESPs are used in zirconium sand for detaching the rutile in plants like dry mills and rutile
6.TRACTION TRANSFORMER
A traction transformer is a large single phase transformer fitted in the locomotive to feed
power to traction motors and other auxiliaries. It takes 25kv AC from overhead line as
primary voltage. This voltage is then stepped down to say 1500volts and fed to a rectifier for
running DC traction motors. Alternatively, output of traction transformer may be fed to
rectifier - inverter set for running three phase AC traction motors.

FIG:7.1 TRACTION TRANSFORMER

BHEL Jhansi unit manufactured single phase TRACTION TRANSFORMER up to
rating 25KV/5400KVA and three phase transformer up to rating 25KV/7475KVA.

CONSTRUCTION OF TRACTION TRANSFORMER

1.CORE:
The constructional features of a traction transformer are more or less same as other power
transformers. The locomotive transformer core is made from cold rolled grain oriented steel of
best grade and provides magnetic circuit. The magnetic circuit consists of a laminated core of
interleaved construction comprising of a three-limbed construction. One of these legs carries
the windings of the regulating transformer with tappings connected to the tap changer and
auxiliary winding for auxiliary circuits. The primary windings of the fixed ratio transformer
and the secondary winding feeding the rectifier traction motor circuits are distributed on two
other legs.
Due to height limitation in electric locomotive, the core is placed horizontally. It also requires
careful tightening of the core, end frames and cores together, to form a rigid assembly,
otherwise there is a possibility of sagging of the core limbs.
2. WINDING:
The regulating winding and auxiliary winding are placed on limbs II and III are provided with
HV and LV windings. The conductors used are of paper covered high conductivity copper
strips. As the numbers of taping leads are large they are carefully insulated and anchored to
prevent movement under mechanical forces. The entire core and coil are held in position by
steel pins at the bottom to prevent shifting of the assembly.
3.INSULATION:
Since insulation is the most important factor for the traction transformer winding, this requires
much attention for the same. The insulation is pre-compressed pressboard, which does not chip
or get crushed under shock loads. The entire coil assembly is carefully shrunk pre-determined
clamping pressure and controlled heat. A further safe guard against any minor shrinkage in
service, spring-loaded pressure pads are employed which exerts a steady pressure on all the
windings through sturdy steel plate. As the space is at premium in electric locomotive, the pre-
compressed intersections insulation is match to close tolerance to avoid coil build-ups.
Insulation angle rings and angle barrier are place between HV and LV winding. These are of
method construction which brings compactness and mechanical strength to the coil assembly.
The insulation blocks are carefully dimensioned and positioned between the windings so as to
ensure adequate strength to the coil and effective cooling. All the bolts and nuts are properly
secured to prevent loosening in service. All leads are suitably clamped to prevent any
possibility of a short circuit due to vibration.
4.TRANSFORMER TANK:
The mild steel tank, oil conservator and cooling pipe work are fabricated to close tolerances to
facilitate their mounting in limited space in the locomotive. In their design, care is exercise to
keep their weight down to bare minimum but at the same time ensuring sufficient strength. The
tank ring and cover are carefully matched to ensure oil tightness under the worst operating
condition encountered during acceleration or retardation of the locomotive, which brings in
additional oil pressure at the joints. The cover suspended transformer is provided with special
screws to adjust the height of the assembly, so that in fully tighten position it sits evenly on the
base pads.
5.Protection System Fittings :
The traction transformer has in built system of protection for maximum safety in service.
This is achieved by a number of protective devices such as oil and airflow indicators in
cooling circuit. The separately mounted CT in primary circuit ensures protection against
excessive overload and short circuits. The primary side is protected from the voltage surges
by means of arcing horns place on the roof of the locomotive. The auxiliary winding and
associated equipments which are subjected to sudden rises in voltage are protected by surge
condensers connected across the winding. The breather, which prevents the ingress of
moisture, is also of a special construction. The breather has special shaped nozzle at the
entrances to filter out the heavy particles. The transformer is provided with a condenser
bushing / cable head termination bushings for the connection to 25 kV traction supply. All
other HV, LV, auxiliary bushings are of porcelain type and are mounted on the top of the
tank cover.
6. COOLING ARRANGEMENT:
To bring in desired compactness, the coolers are always of forced oil forced air type (OFAF).
The rate of oil flow and position of inlet and outlet of the oil from the transformer are governed
by consideration of optimum cooling. The oil pump is of glandless type construction and is
based near the oil outlet. The oil from the coolers enters the transformer at the bottom and then
rises to the top near the outlet. To facilitate servicing and replacement of major components in
the cooling circuit the valve are introduced at the appropriate places. The complete cooling
equipment is mounted on the cover of the transformer. It includes an oil cooler, an oil pumping
set and the blower of the oil cooler. The conservator is fitted to the top of the transformer
through a pipe. At the top of conservator a spring loaded safety valve is fitted. Above this safety
valve, there is an oil overflow chamber with a discharge pipe which discharges the oil down
underneath the locomotive body. The oil pump and the cooler are both connected to the
conservator by a venting pipe. The air does not come into contact with oil in the conservator
directly, and is dried before by means of a silica gel air dryer.

APPLICATION
These transformer are constructed for locomotives which drive the mo tor and other
auxillaries.