A Mini Project On CAST RESIN TRANSFORMERS Manufacturing and Testing

Carried out at M/s Vijai Electricals Ltd, Hyderabad (works at Rudraram) during 21-06-2010 to 08-07-2010. Under the guidance of Sri. V. Koteswara Rao, Consultant and Trainer Centre for Education, Training and Development. By D.Nagamani Devi (Regd no:07071A0235) U. Sundeep (Regd no:07071A0253) L. Sridevi (Regd no:07071A0254)
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

Vnr Vignana Jyothi Institute of Engineering and Technology (Approved by A.I.C.T.E., New Delhi & Govt. of A.P. & Also to J.N.T.U) Bachupally(v), Hyderabad, A.P., India. E-mail: postbox@vnrvjiet.ac.in, Website: www.vnrvjiet.ac.in

A Mini Project On CAST RESIN TRANSFORMERS Manufacturing and Testing

Carried out at M/s Vijai Electricals Ltd, Hyderabad (works at Rudraram) during 21-06-2010 to 08-07-2010. Under the guidance of

Sri. V. Koteswara Rao, Consultant and Trainer Centre for Education, Training and Development.

ACKNOWLEDGEMENTS
First and foremost, we wish to thank our guides Sri. V. Koteswara Rao & Sri. D. Vijay Bhasker, Engineer, CETD, VIJAI ELECTRICALS LTD. for their enthusiastic support and guidance extended by them without which this project would not have been completed with any degree of success. We also express our sincere thanks to Wg.Cdr. A.Kamalakar, VP (HR) VIJAI ELECTRICALS LTD. for providing us this opportunity to complete the project work successfully. We sincerely thank Associate Prof. Ramesh babu Sir, EEE , VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING & TECHNOLOGY for providing us the support & enough guidance to complete the project work successfully. We also thank Prof. K. Anuradha, Head of the department, Electrical and Electronics Engineering, VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING & TECHNOLOGY, Bachupally for providing us this opportunity to carry out our project work. We express our gratitude to Sri. J. D. Ramesh, Chairman& Managing Director, VIJAI ELECTRICALS LTD. for allowing us to do the project in their organization.

ABOUT VIJAI ELECTRICALS LTD.

Overview Pioneering leadership, remarkable vision, strong customer focus, and a relentless commitment to quality and innovation have made Vijai Electricals Ltd. one of the largest and leading manufacturer-exporters of Power and Distribution Transformers. Ever since its foundation in 1973, Vijai has made an impact in the Electrical Industry and its products have been inspected and accepted by several internationally reputed third-party Inspection Agencies like Lloyds-UK, Crown Agents-UK, BSI Inspectorate Griffith-UK, Bureau Vetitas, OMIC Japan, CAPEThailand, Society General de Surveillance (S.G.S), Tube scope Vecto GmbHGermany, Robert W. Hunt Organization, RITES, AT Survey & Inspection Company-Bangladesh and so on. Headquartered in Hyderabad, Andhra Pradesh, India and operating from stateof-the-art manufacturing facilities, spread over a 160-acre campus, Vijai Electricals Ltd. employs aver 7000 highly qualified, experienced and well trained personnel with an inspiring zeal for hard work and success. Today, with more than three decades of continuous progress behind it, Vijai has crosses many historical landmarks and grown into a progressive global organization surpassing many benchmarks in the field.

Vision Vijai Electricals Ltd. Aims to be a prominent global player and a national leader in the field of Power Transmission and Distribution, promoting the cause of energy saving through constant innovation and customization of products, and introduction of value added solutions for its honored customers. It is getting set to become a one stop shop for Power and Distribution Transformers, scaling newer heights of technology, setting quality benchmarks for all its products and services, and ensuring satisfaction to all its shareholders.

Distribution Transformer Division: CRGO Transformer Plant:

Vijai operated from a chain of facilities based in Hyderabad, Uttarakhand and an overseas unit at Brazil. The manufacturing units of Vijai represent the best form at manufacturing process that is based on the concept of vertical Integration or Backward Integration. This helps us to create an effective system that maintains its good hold on quality. This plant is capable of the following: Small and Medium Range Distribution Transformers Small power oil Filled Transformers Single Phase Transformers Dry type Cast Resin Transformers Corrugated Tank Transformers Completely Self Protected Transformers

 Pad Mounted Transformers

Amorphous metal core distribution plant:

The amorphous metal core transformer plant is one of the most modern and advanced manufacturing capacity of over 1000 units per day comprising of 300 Nos. Three phase transformers and 700 Nos. Single phase transformers. Amorphous Metal Core Transformers reduces the no load component in a transformer by 60 to 70%. This manufacturing unit uses in house developed PLC controlled semi automatic winding machines, Hot Air Blowing Machines, oil filling under vacuum arrangement which is complemented by complete test set up including High Voltage Impulse Lab and Short Circuit Lab for type testing the transformers.

EHV and Large Power Transformers Division:

Having excelled in the field of Distribution and Power Transformers, Vijai has now stepped in the arena of EHV Large Power Transformers. This plant of Vijai Electricals Limited is most contemporary with state of the art manufacturing facilities that would be required to manufacture the end product.

Vijai Electricals Ltd. has pulsed in design, manufacturing, testing and supply of EHV Power Transformers up to 500 MVA, 500 kV class in technical collaboration with M/s Daihen Corporation, Japan.

Switchgear Products Division:

Vijai was established for the manufacture of wide range of Switchgear products from 12kV to 420kV and Instrument transformer from 12kV to420kV and Vacuum interrupters up to 36kV, Gas Insulated Substations up to 220kV as below; Medium Voltage Vacuum Switchgear Medium Voltage Gas Insulated Switchgear Medium voltage Current Transformers Medium Voltage Potential Transformers Medium Voltage VCB Kiosk

EHV Live Tank EHV Dead Tank

Circuit Breakers Circuit Breakers

EHV Gas Insulated Switchgear EHV Current Transformers EHV Voltage Transformers Vacuum Interrupters

Projects Division:
The projects wing started operation from the year 2003 and now it is carrying out major projects in Transmission and Distribution of Power all over India. This division of Vijai is mainly crafted for:

 Rural Electrification works (RE) Substation works Overhead Transmission Lines DTR packages High Voltage Distribution System (HVDS) Consultancy

Sister concerns
Improving quality &Efficiency through Vertical Integration

Samrakshana Electricals Limited:

Samarakshana Electricals Ltd. (SEL), a sister concern of Vijai Electricals Ltd. provided support to Vijai by manufacturing and supplying almost all major components that go into the making of Transformers. This helps Vijai to get an edge over competitors in terms of quality, price and delivery schedules, while maintaining an effective and complete control on the entire supply chain. SEL is well known for the quality of its products and effectively caters to the needs of various national and international customers besides meeting the requirements of Vijai.

Awards
In recognition of Outstanding Excellence

 Udyog Patra Award from Vice President of India in the year 1982. Udyog Ratna Award from the then Union Minister of Energy, Govt. of India in the year 1987. Certificate of Merit from EEPC for outstanding Export for the years 1992, 1993 and 1994. All India Award for Export Excellence by EEPC for the years 1994-95, 1995-96, 1996-97. Rolling Trophies for Export by Confederation of Indian Industries (CII), continually for four years beginning from 1994 to 1997. Recognition as Export House in 1993-94 by the Govt. of India. EEPC Regional Award for the outstanding Export Performance during the year 1999-2000 (Under the category Electrical Power Machinery, Switchgear and Control gear). National Citizens Award for the year 1998 received by our Chairman for outstanding contribution in the field of Industry. Udyog Jyothi Award from the then Minister of Labour & Employment, Govt. of India in the year 2000. Award for the best Export Effort in the State ( Surana Udyog Silver rolling Trophy) during 2001-02 from the FAPCII. ITID (Institute of Trade Industrial Development) Quality Excellence Award 2002 awarded in recognition of Quality Product (Amorphous Metal Transformers) by ITID, New Delhi.

4th Best Exporter Award for the year 2001-2002 from container corporation of India, Ministry of Railways, Govt. of India.

Bharat Ratna Dr. M. Veisvesvaraya Industrial Award 2003 for Best Import Substitution Effort All India Manufacturers Organization, A.P. EEPC Regional Award for the outstanding Export Performance during the year 2000-2001. EEPC Regional Award for the outstanding Export Performance (Continuous Excellence) during the year 2001-2002. EEPC Regional Award for the outstanding Export Performance (New/Difficult Market) during the year 2002-2003. EEPC Regional Award for the outstanding Export Performance during the year 2005-2006.

Centre for Education, Training and Development

1. Vijai Electricals has always seen Training and Development as a part of the heart of business and committed to be a learning organization. 2. The Centre for Education, Training and Development (CETD) has been created to facilitate nurturing the learning culture of the people and empowering them to build the company into a knowledge enterprise.

3. CETD facilitates and co-ordinates

Regular in-house education and training programmes for newly appointed personnel of different disciplines utilizing the services of experienced and Knowledge able managers of VEL as faculty and also external faculty from reputed organizations.

In-house refresher courses for professional development.

In-house programmes for enhancing essential skills for executives and managers for organizational effectiveness utilizing the services of experienced and knowledge able managers of VEL as faculty and also external faculty from reputed institutes.

External training programmes at premier institutes in the country and enterprises abroad for achieving individual and organizational excellence.

4. The objectives of CETD are redefined so as to work in unison with HR department in the following areas. Continuing professional development of people for global competitiveness. Performance management system for performance improvement.

Fostering talent. Creating a welcome environment where people want to stay. Building a knowledge enterprise. Developing the leadership pipeline through continuous improvement, succession depth, and reducing retention risk. # (Annexure).

5. CETD has been developing managers as teachers. They Counsel. They give young managers constructive advice and feedback. They use younger managers as sounding boards. They Excel. Where in finance, production or marketing, these managers are the best in some aspect of their business. They give Exposure. They make sure that the work and accomplishments of young managers are seen. They open doors for them. They provide latitude. They give young managers freedom to try, the courage to fail. They involve them in important tasks. They are tough taskmasters. The challenge; they demand excellence.

6. CETD has introduced Socratic method of teaching in various units of the organization. Socratic method calls for small group environment. Each of the functionaries in supervisory role is required to engage his team members in a dialogue in the tradition of Socrates. Socrates, you may be aware, was a philosopher, always searching for truth. To him the only thing worth having was true knowledge, and he often discussed difficult questions with his friends and acquaintances, so that out of the discus-

sions truth might emerge. He had many disciples or chelas. The managers are encouraged to take leading role in facilitating such group meetings. These meetings would enable functionaries in supervisory role to become responsible workers defined by Peter F Drucker as persons committed to getting the results.

7. CETD has Training Centers at Corporate Office and Rudraram. The facilities include classrooms for conducting in-house training programs with a total seating capacity of 300. 8. CTED has Information Centers at corporate level and at Rudraram. These provide facilities for reading and sharing information for new knowledge. With a view to developing departments as Knowledge Centers, which will be the building blocks for the company to become knowledge enterprise, it has set up information centers at S.B. Unit and departmental level also. These are managed by Executive Assistants to Heads. A fortnightly e-journal A Time to Think is being bought out regularly, under the guidance of Sri. T. Sugunakara Rao, Advisor, VEL.

INDEX

1. 2.

ABSTRACT INTRODUCTION OF TRANSFORMERS 2.1. 2.2. 2.3. 2.4.

3.

Definition Working principle EMF equation Equivalent circuit of transformer

DRY TYPE OR CAST RESIN TRANSFORMERS MANUFACTURING PROCESS OF CAST RESIN TRANSFORMER 4.1. 4.2. 4.3. Flowchart of manufacturing process Core making or core assembly Windings 4.3.1. 4.3.2. 4.4. 4.5. Casting of coils Enclosures HV winding LV winding

4.

5.
6.

TESTING OF CAST RESIN TRANSFORMER CHARACTERISTICS OF CAST RESIN TRANSFORMER CONCLUSION

7.

ABSTRACT

Cast resin transformer is non flammable with high anti-heat strength. It is especially suitable for places of denser electricity consuming or the places that specially require safety, such as residence houses or office buildings, department stores, hospitals, schools, stations etc. Therefore, the importance of the cast resin transformer has gradually been enhanced in the territory of power-distribution system. In this project the manufacturing process and testing of cast resin transformer is studied. The manufacturing process includes: 1. Core assembly. 2. Winding. 3. Casting of coils. 4. Enclosures. In testing we have studied different tests like induced over voltage test, insulation resistance test etc.

Definition:

Alternating voltages can be raised or lowered as per the requirements in the different stages of electrical network as generation, transmission, distribution and utilization.

This is possible with a static device called transformer. The transformer works on the principle of mutual induction. It transfers an electric energy from one circuit to other with the desired change in voltage and current, without any change in the frequency, when there is no electrical connection between the two circuits.

PRINCIPLE OF WORKING:

Principle of mutual induction:

It states that when two coils are inductively coupled and if current in one coil is changed uniformly then an emf gets induced in the other coil. This emf can drive a current, when a closed path is provided to it. The transformer works on the same principle. When primary winding is excited by an alternating voltage, it circulates an alternating current. This current produces an alternating flux which completes its path through common magnetic core. Thus an alternating flux links with the secondary winding. As the flux is alternating, according to the Faraday's law of an electromagnetic induction, mutually induced emf gets developed in the secondary winding. If now load is connected to the secondary winding, this emf drives a current through it. Thus though there is no electrical contact between the two windings, an electrical energy gets transferred from primary to the secondary.

Fig. 02

E.M.F EQUATION OF A TRANSFORMER:

When the primary winding is excited by an alternating voltage V1, it

circulates alternating current, producing an alternating flux. The alternating flux linking with the primary winding itself induces an emf in it denoted as E1. The same flux links with the secondary winding through the common magnetic core. It produces an induced emf E2 in the secondary winding. This is mutually induced emf. = flux m= maximum value of flux N1= Number of primary winding turns N2= Number of secondary winding turns f = frequency of the supply voltage E1= R.M.S value of the primary induced emf E2= R.M.S value of the secondary induced emf From Faradays law of electromagnetic induction the average emf induced in each turn is proportional to the average rate of change of flux. Therefore, Average emf / turn = avg rate of change of flux d/dt = change in flux/time required for change in flux In 1/4th time period, the change in flux is from 0 to m. Therefore, d/dt = m 0/ (1/dt) [ Asdt for 1/4th time period is 1/4fseconds ] = 4fm wb/sec For sinusoidal quantity, Form factor = R.M.S value/avg value = 1.11 R.M.S. Value = 1.11*avg value R.M.S. Value of induced emf / turn = 1.11*4fm = 4.44fm As N1 is the number of primary turns hence the RMS value of induced emf E1 is, E1 = N1*4.44fm volts As N2 is the number of turns the RMS value of induced emf E2 is, E2 = N2*4.44fm volts

Equivalent circuit of transformer:

The term equivalent circuit of a machine means the combination of fixed and variable resistances & reactances, which exactly simulates performance & working of the machine. For a transformer, no load primary current Io has two components. They are: Im = Io sin o Iw = Io cos o

Iw

Im

Fig. 06 Equivalent circuit of transformer Im produces the flux and is assumed to flow through reactance Xo called "No load reactance" while Iw is active component representing core losses hence is assumed to flow through the resistance Ro. This circuit consisting of Ro & Xo in parallel is called "exciting circuit". When the load is connected to the transformer then secondary current I2 flows. This causes voltage drop across R2 & X2. Due to I2, primary draws an additional current I'2 = I2/K Now, I1 is the phasor addition of Io & I'2. This I1 causes the voltage drop across primary resistance R1 & reactance X1.

Types and Applications of transformers:

Autotransformer An autotransformer has only a single winding with two end terminals, plus a third at an intermediate tap point. The primary voltage is applied across two of the terminals, and the secondary voltage taken from one of these and the third terminal. The primary and secondary circuits therefore have a number of windings turns in common. An adjustable autotransformer is made by the secondary connection through a sliding brush, giving a variable turns ratio. Polyphase transformers For three-phase power, three separate single-phase transformers can be used, or all three phases can be connected to a single polyphase transformer. In this case, the magnetic circuits are connected together, the core thus containing a threephase flow of flux. The three primary windings are connected together and the three secondary windings are connected together. The most common connections are Y-, -Y, - and Y-Y. If a winding is connected to earth (grounded), the earth connection point is usually the center point of a Y winding. Instrument transformers A current transformer is a measurement device designed to provide a current in its secondary coil proportional to the current flowing in its primary. Current transformers are commonly used in metering and protective relaying, where they facilitate the safe measurement of large currents. They are designed to present negligible load to the supply being measured and to have a precise voltage ratio to accurately step down high voltages so that metering and protective relay equipment can be operated at a lower potential. Oil filled transformers Oil-filled transformers are transformers that use insulating oil as insulating materials. The oil helps cool the transformer. Because it also provides part of the electrical insulation between internal live parts, transformer oil must remain stable at high temperatures over an extended period.

Dry type transformers:

 Dry type transformers require minimum maintenance to provide many years of reliable trouble free service.
Dry type transformers provide a safe and reliable power source which

does not require fire proof vaults, catch basins or the venting of toxic gases. Dry type transformers are a rather mature product and technology but, of all the components in a power system, a transformer replacement can be a physically challenging event, extended delivery of a replacement or repair unit and expensive transportation costs.
Dry type or "cast resin" transformers are well suited for installation in

high rise buildings, hospitals, underground tunnels, school, steel factories, chemical plants and places where fire safety is a great concern.

MANUFACTURING PROCESS OF CAST-RESIN TRANSFORMERS Flow chart:

In this flow chart, the different phases of manufacturing a transformer are showed in an order.

Preparation of core Conductors laminations

Fibre glass insulation

Winding Core assembly Core chamber

LV Windings

HV Windings

Pre-core testing Mould assembly

Core coil assembly Pre-heating

Accessories Casting

Enclosure Curing

This flow chart is showing the processes involved in the coil making.
Demoulding

Cutting and finishing

Core making:
Core and frame construction: The core is made up of highest quality, cold-rolled grain-oriented [CRGO], high

silicon content steel and accurately cut on the latest CNC machines. Three legs of the core are arranged in a single plane and interconnected with a yoke. The legs are arranged in circular structure multi-ply step-wise design, and are carefully interlaced with stepwise epoxy arranged yokes.

Using the step lap technology, the core is miltered at a 45 angle and carefully stacked to obtain very low losses, exciting current and noise. The core is insulated on both sides of each lamination and protected against corrosion by a resin coating and grounded in accordance with required standards. The frame consists of upper and lower steel channels. It holds the core and coil together securely. The core is suitably clamped on a structure so as not to give any vibrations. The clamping structure is tested 2.5 KV for 1 minute with respect to earth. The undercarriage is bolted to the bottom of the lower frame. Wheels enable the transformer to be moved either length -wise or side -wise. Lifting lugs and Grounding terminals are fitted to the upper and lower frame respectively. To protect against corrosion, all steel parts are coated with epoxy paint.

MANUFACTURING PROCESS OF CAST-RESIN TRANSFORMERS I) HIGH VOLTAGE WINDING A) Scope:

This specification describes the requirements for cast resin high voltage cross-over winding up to maximum Outer diameter = 800mm Length = 2000mm Weight 3000Kgs Parallel = 4 B) MANUFACTURING AIDS: i) Machine speed Range Max. weight 9 RPM Up to 10 MVA HV 1200 KGS

ii) Tools: Nylon mallets 1/2 KG size 300 mm shearing scissors 200 mm cutting pliers 6 Number screw spanners OD calliper (spring loaded) Wooden blocks of (50mm x 50mm x 25mm) Bending tools iii) Accessories: Mandrel fixing rod Side flanges Locking nut "C" clamps Oxy-acetylene gas brazing. C) Preparation: KGS

1. Machine is selected on the basis of coil size. If number of parallels is more, slower speed is desirable and vice-versa. 2. Mandrel is picked as per design. Coil ID = Mandrel OD [Note: OD = outer diameter, ID = Inner diameter] 3. Keep tapered mandrel on a stand 1 1/2 feet above the ground. 4. Select mandrel fixing rod suitable to mandrel.
5. Insert rod through a flange and then insert through mandrel ensuring that

smaller OD of mandrel is on the left and flange is on left. 6. Fix mandrel to flange with four M12 bolts. Now insert right flange and fix it with four M12 bolts and tighten it with lock nut.

Mandrel fixed with a left flange

A machine loaded mandrel for winding 7. Lift the mandrel with crane carefully and load it on the suitable machine.

8. Plummer blocks on both sides shall be fixed properly to ensure free rotation of mandrel. 9. Clean the mandrel with emery paper and cotton gauze. 10.Apply the releasing agent QZ13 (silicon oil) all over the mandrel. 11.Wrap polypropylene disconnecting film (0.2 mm thick fully on the mandrel to avoid sticking oil after casting).
12. Wrap fleece and glass mat [Fibre glass tape].

13.Do marking on the mandrel given on winding details chart. 14.Loan the bobbins on the stands as per the arrangement. 1F x 2over 2F x 1over

D) PROCESS:

1. Pass all the conductors through tension stand and bend the starting leads of 300 mm length to Z shape. 2. Take the bent starting leads to the mandrel and tape them to the mandrel at position where windings is to commence. 3. Mark the directions of each coil windings on mandrel. 4. Now start windings as given in design sheet.
5. After completing the pre-segment winding fill the gaps with fibre mat and

wrap insulation. 6. Check the OD with the spring loaded callipers and record in the format.
7. Fix the segment with sides flanges support and ensure (50 mm) uniform

gap between segments. 8. Bend both starting and finishing leads of the pre-segment coils.
9. Fill the gaps with fibre mat and wrap insulation. Check the OD.

10.After completing the coils, do the markings of tap positions on the coils. 11.Then bend the copper sheets at the marked position and braze the M16 or M12 brass. 12.Clean the joints with emery paper and cotton gauze to remove the carbon formation after brazing. Insulate with glass tape and mat 13.Wrap with mat mentioned in the design and do the full taping with 100 mm glass tape. 14.Check the OD and record. 15.Unload the mandrel from the machine and remove the locking nut, flanges and mandrel fixing rod. 16.Now the coil is ready for further manufacturing processes. MANUFACTURING PROCESS OF CAST-RESIN TRANSFORMERS

II) LOW VOLTAGE WINDING This specification describes the requirements of cast resin LV winding up to a maximum outer diameter of 600mm, a length of 200mm, a weight of 2500kgs and up to 60 parallels. MANUFACTURING AIDS: 1. Machine for winding: S.no 1. 2. Tools: Nylon mallets Shearing scissors Cutting pliers Screw spanners OD caliper(spring loaded) Bending tools

Machine speed 9 RPM

Range Upto 10 MVA

Max wt. 1200KG

Vernier calipers : 0-300mm Micrometer : 0-25mm Steel rule : 1meter

3. Accessories: Mandrel fixing rod Side flanges Locking nut C clamps Oxyacetylene gas brazing equipment PREPARATION:

Machine is selected on the basis of coil size. If the number of parallel in a coil is more, then lesser speed is preferable and vice versa. Mandrel is picked as per the design coil ID=Mandrel OD 1mm.

Keep the tapered mandrel on a stand about one and a half feet above the ground level. Select the mandrel fixing rod suitable to the mandrel bore. Insert the rod through a flange and then insert the rod through the mandrel such that the flange is on the left side of the mandrel and ensuring that smaller OD of the mandrel is on the left side.

Fix the mandrel to flange with M12 bolts, insert right side flange and fix it to mandrel with M12 bolts and tighten the rod to mandrel with lock nut.

Lift the mandrel carefully with 5T crane and load it on the selected machine. Proper locking of mandrel fixing rod with plummer block on drive side shall be ensured by means of key provided for this purpose. Plummer blocks on both sides shall be fixed properly to ensure free rotation of mandrel. Clean the mandrel properly with smooth emery paper and cotton waste. Apply releasing agent (silicon oil) with the brush moderately throughout the mandrel. Wrap the polypropylene disconnecting film of 0.2mm thickness fully on mandrel to avoid sticking of coil to mandrel after casting.

Then wrap fleece and glass mat as required by design with fibre glass tape.

Then do the marking on mandrel as given in the winding detail chart.

Process:

1. Pass all the conductors through the tensioners and arrange in a line as per the winding arrangement.
2. Tie each set of parallels which are in OVER position separately and ar-

range them in descending order from left to right with a gap of 20mm between the tips of each set. 3. Keep all the conductors tight in tensioner and bend them to L shape with the bending tools for starting leads. 4. Tape all the conductors with 30mm tape (FG) separately & together as one bunch. 5. Winding shall start from right to left while the machine drive is on left side. 6. Then clamp the conductors to the mandrel at start point on right side with C clamp by keeping supporting wooden blocks between the clamp & conductor and clamp and mandrel. 7. Ensure proper tightening of C clamp to avoid displacement of conductors from start point, while winding in tension. 8. Start winding from right to left. 9. Keep the gap between turn to turn as given in winding details chart. 10.Do the transposition at mentioned turns.
11. Ensure proper insulation at transposition by taping & keeping fleece

between conductor to conductor. 12.On completion of transposition check the continuity between each conductor, continuity should not come in between any of the parallels.
13. Complete the first layer. Fill the inter turns gap with mat such that the

filling is flush with the conductor level. Keep the fibre glass edge strips on left and right sides. 14.Then remove the C clamp at the start bending, and tie the conductors with polster tapes to avoid displacement of its start position. 15.Then wrap the mat & fleece as required by design. Check the OD and recorded in the format.

16.Fix the segments on first layer with clamping bolts. While fixing the segments ensure equal gaps between them. Then fill the gaps with fibre glass mat. 17.Wrap the insulation on segments as mentioned in design chart. Check the OD & record it in the format. 18.Start the second layer and follow the same procedure as mentioned above. After completing the last turn clamp the conductors with C clamp.
19. Then cut the conductors by keeping required bending length for finishing

lead, as point B in other direction. 20.Then bend the finishing leads to L shape exactly over the starting leads. Tape all the conductors separately & then together as a single bunch. 21.Then tie them with fibre glass tape and remove the C clamp. Wrap mat & fleece as per design. Check the final OD and record in format. 22.Unload the mandrel from the machine & remove the nut, flanges & mandrel fixing rod.

2)

CASTING OF COILS:

1. Before casting process the coils are placed in moulds. 2. These moulds are semi-circular shaped. 3. They have tapings at the bottom and these are connected with the pipes for filling the resin. Resin is filled from bottom to top. 4. Depending on the coil size or width moulds are selected and the holes on the side of the mould are closed with nuts depending on the height of the coils. 5. The resin used is of epoxy type with thermal class F, for a temperature rise of 100K (the temperature of the insulating system being 155C). 6. The casting system prepared for our manufacturing installation contemplates the use of four principal components: Epoxy resin. Filler material. Hardener.

Colouring 7. The mixture of resin and hardener, with the filler material, is degassed under vacuum and at controlled temperature, before a final mixing.
8. Then it is introduced into the moulds under vacuum.

9. After the casting is done in vacuum, the coils are subjected to 18 hours of exposure to various temperatures. Duration 3 hours 5 hours 3 hours 3 hours 4 hours temperature 110oC 80oC 90oC 110oC 140oC

10. This heating will help in filling up the air gaps or cracks formed

during removal of mould. Images of coils after finishing and cutting

11. Then the next process is finishing. Here the coil is given a

smoother finish by removing the extra resin formations. 12. Then the mandrel is pulled using an mandrel puller machine. 13. Then the tapings are given as per the customer requirement. 14. Now the coil is ready to use, it is then enclosed and testing is done.

3. ENCLOSURES:

Enclosures are generally manufactured from zinc coated steel sheet. For very onerous conditions these may be replaced with any other special materials. The standard finish is a polyester based powder coat. The protection categories as per relevant IP number can be provided based on customer requirement. Enclosures are made on most modern computerized metal sheet working machines.

FITTINGS: All the transformers are provided with the following fittings. Standard Features 1) Rating Plate. 2) Lifting Lugs. 3) Under Base. 4) Earthing Terminals. 5) Temperature Monitoring relay. 6) Jacking Pads wherever required. 7) HV and LV Cable Box. Optional Features 1. 2. 3. 4. 5. 6. 7. 8. Winding Temperature Indicator (scanning unit). Remote Winding Temperature Indicator. Uni /Bi Directional Rollers. Monitoring equipment with temperature indication and alarm and tripping contacts. Forced cooling equipment. Plug-in connections. Device for tapping changeover. Metal casing, protection IP31.

VENTILATION:

In order to avoid excessive and damaging heating, and for correct operation, it is essential to dissipate the thermal energy produced by the transformer during operation. The natural circulation of air is directed from the lower part to the upper (chimney effect) and the dimensions of the openings are according to the losses to be dissipated and the temperature of the air entering and leaving the cell. The lower opening must be located close to the transformer, as low as possible, while the upper one must have a cross-section 15% greater to compensate for the lesser density of the hot air.

Calculation for heat dissipation and protection:

The amount of air needed can be calculated according to the following formula: Vin = Pt/1.15 x (m/s) The net surface of the lower grille is given by the formula: A = 10,752 x (Pt/ ) (m) Where: Pt = Total losses to be eliminated in KW. = difference of temperature in C. Vin = air intake in m/s passing through the opening. H = distance in meters between the mid-point of the transformer and the mid point of the upper opening o the cell. A = net surface in m (excluding the grille) of the lower opening.

TESTING OF TRANSFORMERS:
The structure of the circuit equivalent of a practical transformer is developed earlier. The performance parameters of interest can be obtained by solving that circuit for any load conditions. The equivalent circuit parameters are available to the designer of the transformers from the various expressions that he uses for designing the transformers. But for a user these are not available most of the times. Also when a transformer is rewound with different primary and secondary windings the equivalent circuit also changes. In order to get the equivalent circuit parameters test methods are heavily depended upon. From the analysis of the equivalent circuit one can determine the electrical parameters. But if the temperature rise of the transformer is required, then test method is the most dependable one. There are several tests that can be done on the transformer. However a few common ones are discussed here.

Now the test discussed here are:

Measurement of insulation resistance. Induced over voltage withstand test. Measurement of voltage/turn ratio test. Measurement of winding resistance test. Measurement of no load losses (using two-wattmeter method). Measurement of load losses (using two-wattmeter method).

MEASUREMENT OF INSULATION RESISTANCE

Scope: 1. To ensure proper dryness of the active parts and 2. To ensure sufficient clearance between windings and windings to earth. Equipment required: S no. 01 Equipment Insulation tester Recommended Make Range 500v/1000v/2500v/ Yokogawa / Meggar / 5000v Motwane 0-2000m/5T accuracy 3%

Procedure: Insulation resistance shall be measured between windings, windings and tank with a meggar. The insulation resistance varies inversely with the temperature. Therefore the oil temperature shall be recorded. Therefore IR values shall be measured at ambient temperature. Insulation resistance test shall be made as follows: 1. Short all HV and LV terminals separately. 2. Connect insulation resistance meter between shorted HV-LV terminals. 3. Select suitable voltage range of the meter depending upon the voltage class of the winding under test. 4. Apply the voltage and hold for 1min to reach the steady state. 5. Record the IR value as indicated by the meter.
6. Repeat the procedure 2 to5 to get the IR value between HV-Earth and LV-

Earth.

Highest voltage for equipment Um (kV) Withstand voltage AC (kV) Basic insulation level (kV)

3,6 10 20

7,2 20 40

12 28 75

24 50 95

36 70 145

CIRCUIT DIAGRAM:

HV to LV

HV to BODY

LV to BODY

M- Insulation resistance tester[Megger meter] Dos and donts: 1. The DC voltage applied shall not exceed the R.M.S low frequency applied voltage. 2. After the test has been completed all terminals should be grounded for enough time to allow any trapped charges to decay to a negligible value. RESULT:

Terminals connected to megger HV to LV HV to ground LV to ground

Resistance 2000M 2000M 2000M

INDUCED OVER VOLTAGE WITHSTAND TEST

Scope: To check adequacy of inter turn/inter layer insulation of the windings. Equipment required: S no. 01. 02. Procedure: This test is intended to check the inter-turn and line end insulation as well as main insulation to earth and between windings. For transformers with uniformly insulated windings, the test voltage is twice the corresponding rated voltage at double the rated frequency. For 3- transformer with test voltage up to 66KV, generally 3- source is directly applied. When the test frequency exceeds twice the rated frequency, the duration of the test shall be determined by the following formulae: Test duration in sec = 120*(Rated freq/test frequency) Test duration should not be less than 15sec, since the applied voltage is more than the rated voltage, frequency also must be increased atleast by the same proportion as that of voltage so as to keep the flux density within the rated value. The minimum test frequency condition = (Et/1.1*Ec)*rated frequency Where Et = Induced voltage across winding Ec = Rated voltage across the winding Equipment 10vw test set Stopwatch Make AE/RE/ Kirloskar Taksun Recommended Range 0-1000v, 0-100/200hz 0-10 min Accuracy 0.5 0.5 sec

CIRCUIT DIAGRAM:

Observation: The voltage is applied for 30seconds of duration. Applied voltage = 866 V. Frequency = 200 Hz Current = 1.33 A RESULT: The transformer withstood for 30sec at a frequency of 200 Hz.

MEASUREMENT OF WINDING RESISTANCE

Scope: To calculate I2R losses of the winding To ensure proper crimping, brazing & other connections Equipment required: S. no 1 2 Procedure:
1. For calculation of I2R losses in the windings, it is necessary to measure

Equipment Transformer winding resistance meter Thermometer

Recommended Make MultiAmp/eltel/Tinslay Dimple/sita/zeal range accuracy

DC resistance of each winding. 2. The resistance measurement shall be done by circulating the direct current in the winding and after it has reached a steady state value. 3. In some cases this may take several minutes depending upon the winding inductance. 4. The time taken can be a reference for hot resistance measurement at the time of temperature rise test. 5. Temperature of the winding should be stable and for this reason, the test shall be carried out normally before the load loss measurement rise test. 6. The ambient temperature shall be recorded. 7. The measurement of winding resistance shall be done using transformer ohmmeter. Acceptance criteria: a) Winding resistance should be less than the guaranteed value. b) Resistance of each phase should be nearly equal. c) Resistance value from highest winding tap to lowest winding tap should be in descending order.

CIRCUIT DIAGRAM:
A

HV Winding resistance Equivalent circuit of HV winding

DC

Total resistance = 3R/2. Where as, R is the resistance of each phase winding.

 Single resistance equivalent of HV winding A

DC

LV Winding resistance

Result:
The resistance of each winding is obtained as follows: For ex. D.C supply is 10v and the current flowing through each resistance is 2A then R = V/I = 10/2 = 5ohms. Therefore equivalent resistance of H.V winding is 3R/2. 3R/2 = 15/2 = 7.5ohms.

MEASUREMENT OF VOLTAGE/TURNS RATIO

Scope: To ensure number of turns in different windings. Equipment required: S. no 1. Equipment Transformer ratio meter Make Eltel /biddle Range 0.80-2021 Accuracy 0.1%

Procedure: 1. Any convenient voltage shall be applied on HV winding and voltage on HV & LV shall be measured.
2. Two voltmeters shall be used, one to read the voltage of the high-voltage

and the other, the low voltage winding. 3. The two voltmeters shall be read simultaneously.
4. A second set of readings shall be taken with the instruments interchanged,

and the average of the two sets of readings are taken to compensate for instrument errors. 5. The ratio of voltages on HV winding to LV winding should be declared as the ratio of transformer.

CIRCUIT DIAGRAM:

RESULT:
Turn`s ratio Applied voltage (at primary) Observed voltage (at secondary) 25.4 500V 19.68V

MEASURMENT OF NO-LOAD LOSSES (USING TWO-WATTMETER METHOD)

Scope : To estimate energy loss of the transformer at rated voltage. To assess the efficiency of the transformer. Equipment required : S.n o 1 2 Power analyzer 3 4 Current Transformer Potential transformer Recommended Equipment Variable voltage & variable frequency MG set Make Kirloskar/ AE/ RE Yokogawa/ Voltech/ AV power Any reputed make Any reputed make Range 0-1000V, 0-100A, 0-100Hz. 0-600V, 0-20A. 10-5/1A 11000V/110v Accuracy _ 0.2 0.2 0.2

Procedure :
1) The measurement of the no-load loss & current is important not only for

the purpose of assessing the efficiency, but it is also a check to see that the high voltage has not caused any damage to insulation.
2) Therefore for large transformers this test shall be carried out before and

after completion of the "Dielectric test".

3) Measurement of no-load loss shall be done at rated frequency, usually by

applying rated voltage to low voltage winding and opening high voltage winding.
4) As no-load current is less, I2R losses will be negligible. The core losses

consists of hysteresis and eddy current losses.

5) The hysteresis loss is directly proportional to supply frequency 'f' and

eddy current loss is directly proportional to square of the supply frequency.

6) Hence, test is done at rated frequency.

CIRCUIT DIAGRAM:

RESULT:
No load losses are obtained. Applied voltage Observed current No-load loss 250V 230mA 68.29W

MEASURMENT OF LOAD LOSSES (USING TWO-WATTMETER METHOD)

Scope : To estimate energy loss of the transformer at rated voltage. To assess the efficiency and voltage regulation the transformer. Equipment required : Recommended Make Range 0-11000V, Kirloskar/ AE/ 0-100A, RE 0-100Hz. Yokogawa/ 0-600V, Voltech/ AV 0-20A. power Dimple/ Sita/ 0-50oC Zeal Any reputed 10-5/1A make Any reputed 11000V/110v make

S.no 1 2 3 4 5

Equipment Variable voltage & variable frequency MG set Power analyzer Thermometer Current Transformer Potential transformer

Accuracy _ 0.2 1 oC 0.2 0.2

Procedure : 1) This test is done by shorting any of the windings, mostly LV winding is shorted and rated current is circulated in the HV winding. 2) This measured loss has small amount of core loss, which is negligible, since impedance voltage is a fraction of rated voltage. Load loss = [measured loss at test current*(Rated current/test current)2] (at rated current) 3) While measuring losses, reading must be taken quickly.

CIRCUIT DIAGRAM:

RESULT:
Load losses are obtained. Applied voltage Short circuit current Load loss 471.7V 5.3A 1.32KW

CHARACTERISTICS OF CAST RESIN TRANSFORMERS:

MOISTURE PROOF The complete casting of HV and LV coils under vacuum prevents the penetration of moisture into the winding and the break-down by ionization. Therefore, it is suitable for both storage and operation in adverse environments, including prolonged storage in up to 100% humidity and is capable of being energized immediately after such storage without drying. NO PARTIAL DISCHARGE There is no possibility of partial discharge in CAST RESIN transformers. Each high voltage coil is individually tested for partial discharge before assembly to ensure a partial discharge-free operation under all circumstances, and to guarantee the life expectancy of the insulation system. CAST RESIN transformers are free of partial discharge at least up to 1.2 times of the rated voltage, and no visible corona at 2 times the rated voltage. IMPULSE VOLTAGE STRENGTH CAST RESIN transformers have impulse levels equal to liquidimmersed transformers. The coils are very resistant to impulse voltage. Impulse withstand levels to 200kv are available because of careful design and special structure. The impulse voltage stress of the HV coil is evenly distributed throughout the winding due to a suitable winding arrangement. SHORT CIRCUIT RESISTANT The dynamic short circuit strength of a CAST RESIN transformer is greatly superior to that of liquid-immersed or dry type transformers. In the event of a maximum short circuit, CAST RESIN transformers are not endangered mechanically, due to the dense glass fibre filling and the adhesion of epoxy resin to the conductors. In case of a short circuit, the conductors heat up much faster than the surrounding insulation. Therefore only a strong glass fibre

reinforced design, as found in cast resin transformers can prevent cracking of the coils and failure. THERMAL SHOCK RESISTANCE Tensile and bending strength of glass fibre reinforced epoxy resin (used in the CAST RESIN design) is appreciably higher than that of quartz powder filled resin (used by mostly other manufacturers) has the disadvantage of becoming brittle and tending to crack when exposed to low temperature. Due to the complete combination of epoxy resin and glass fibre, even the worst temperature fluctuation will not induce the cracking of the coils in CAST RESIN transformers. OVERLOAD CAPABILITY Based on the high thermal time constant factor of the windings, CAST RESIN transformers can be overloaded for considerably longer periods of time than liquid immersed or dry type transformers. It has a greater capability to withstand sudden momentary high overloads such as might be encountered in heavy traction or severe duty industrial applications. FIRE RESISTANT CAST RESIN transformers have an inherently safe characteristic of self fire-extinguishing and fire resistance. So there would be no fear of spread of fire even if a fire took place in near by equipment. The transformers can be used indoors without fear of fire, and it is not necessary to provide additional measures for safety.

 MAINTENANCE FREE Maintenance is almost completely eliminated. No checking of liquid level and no yearly dielectric test for moisture absorption is required. Due to the smooth coil surfaces, heavy dirt and dust build up is eliminated even under the worst circumstances. The recommended routine maintenance is an occasional visual or InfraRed thermal inspection. ENVIRONMENTALLY SAFE CAST RESIN transformers will not emit oil or toxic gases into the atmosphere. Therefore, they do not pollute the environment and are recommended strongly as a replacement for arsenal filled (PCB) transformers. PCB is poisonous, chemically aggressive and can discharge dangerous gases at elevated temperatures. LOW NOISE The encapsulation of the core in a special resin and the design of the clamping mechanism have provided an appreciable noise reduction. Noise is also reduced due to the sound suppressing effect of the elaborate core cutting and the coil support elastic structure. COST SAVING If the advantages of CAST RESIN transformers are taken into consideration at the planning stage, the overall costs of a power supply system can often be considerably reduced. They are sufficiently compact for convenient installation in a building where space is generally limited and have much smaller power loss than oil- immersed and dry-type transformers. Total costs are lower even though cast resin transformers may be more expensive than other transformers. Cost savings add low maintenance and longer operating life in all conditions.
LESS FAILURE RATE

Standard Insurance Company studies have shown failure rates in

cast coil transformers to be less than 5% that of standard dry type transformers in some applications.

Conclusion:

As we know that the general oil filled distribution transformers are having many disadvantages. So cast resin transformers came into field of power distribution making the distribution more reliable and safer. These transformers are indoor type transformers. Now-a-days the use of Cast resin transformers has been increased and they are widely used in power houses, Apartments, as back-up supply, etc.,

References:

A book on Transformers by Bimbhra.

A book on Transformers by J. B. Gupta. Wikipedia.org Google.com

Material and guidance by Mr. V. Koteswara Rao, CETD.