WEL-COME

TO
POWER GRID OFFICIALS
DESIGN & DEVELOPMENT OF
POWER TRANSFOMERS



Presented by-
J.K.JAIN Sr.DGM(TRE)
Special Characteristic Features of
Transformer Designs
Tailor made designs to suit customer requirements.
Design Problems Two fold.
> Associated with high voltages (Dielectric design,
behaviour under transient voltages, PD).
> Associated with high currents (Electromagnetic.
problems related to stray losses and hot spots,
thermal design, mechanical short circuit forces).

High cost of losses demand low loss designs
with high material content (Transport and
handling problems), better methods of stray
loss control.
No two designs of same MVA and Voltage
rating are comparable in terms of weights and
losses owing to different capitalization,
Impedance, Tapping range, Limiting current
densities, Flux density etc.
Constituents of a Transformer
Windings
Core
Insulation Structure
Tank
Cover
Core clamping Structure
Pipe Work
Cooling Equipment


Bushings
Leads (Terminal Gear)
Fittings
Control Equipments
Oil
Type of Windings
SPIRAL WINDING
HELICAL WINDING
CONTINUOUS DISC WINDING
PARTIALLY OR FULLY INTERLEAVED
DISC WINDING
SHIELDED LAYER WINDING
Type of Windings
Spiral winding Helical winding
(No radial duct)
(a) cross-section (b) connections
SINGLE LAYER DISC COIL

INTERLEAVED DISC
WINDING
INTERLEAVED DISC WINDING
(4 discs per group)
Transposition
Transposition at each cross-over in
Continuous Disc Winding
Transposition in Spiral/Helical Winding
(a) Complete Transposition
(b) Partial Transposition
Directed Oil Flow Arrangement
WINDING

USE OF SPECIAL TYPE OF COPPER
CONDUCTORS (BUNCHED PICC, GLUED
PICC, WORK HARDENED etc.)
OPTIMUM WINDING PLACEMENT
USE OF GUIDED OIL FLOW AND FORCED
DIRECTED OIL FLOW IN WINDINGS FOR
CONTROL OF HOT SPOTS
USE OF YOKE SHUNT/WALL SHUNTS/FLUX
TRAP TO CONTROL STRAY LOSSES

DESIGN TRENDS IN RECENT YEARS

USE OF INTERLEAVED/PARTIALLY
INTERLEAVED DISC WINDING (LAYER
WINDING, IN SPECIFIC CASES)
OPTIMISATION OF RADIAL CLEARANCES BY
STRESS DISTRIBUTION CONCEPT INCLUDING
TG & BUSHING CLEARANCES
OPTIMISATION OF AXIAL CLEARANCES AND
USE OF INSULATION MOULDINGS
REDUCTION IN SOLID PRESS BOARD
INSULATION BY SUB-DIVIDED BARRIER
ARRANGEMENT
Insulating Area
A: Vertical Area B: Horizontal Area C: Area between A&B
Core Nomenclature
L= Leg Length
C= Distance
between leg
centres
W=Main leg
width
Top Yoke
Bottom Yoke
Auxiliary
Limb
W
A A
L
C
C
D= Max. core diameter
Section through A-A
Cooling Duct

D
W
Type of core forms
Single Phase, Core type 2 legs wound
SC
W
W
L
Single Phase, core type middle leg wound
SM
W
W/2
W/2
Single Phase, core type 2 middle legs wound
SMC
W W
W/2
W/2
Three Phase, core type
TC
W
W
W
W
Three phase, core type, 5 limb
TCF
0.43 W
0.57 W
Inside Yoke Length
W
W
W
Core Constructions
A. Three phase- 3 limb core
INTERLEAVED THREE QUARTER MITRED
FULLY MITRED
FULLY MITRED SPLIT WITH
DIAMOND INSERT
Three phase, five limb core
B: Three phase, five limb core
FULL WIDTH
SPLIT WIDTH
CORE:
USE OF BUTTON SPACERS IN CORE FOR BETTER SPACE
FACTOR AND OIL FLOW
USE OF HI-B GRADES OF STEEL FOR REDUCTION OF NO LOAD
LOSSES
USE OF LASER SCRIBED CORE STEEL FOR FURTHER LOSS
REDUCTION
USE OF NON-MAGNETIC STEEL FOR CLAMP PLATE FOR
HIGHER CAPACITY TRANSFORMER FOR STRAY LOSS
CONTROL AND IMPROVED OVERFLUXING CAPABILITY
ELIMINATION OF YOKE BOLTS
REDUCED NO. OF PACKETS IN YOKE FOR IMPROVED
PRODUCTIVITY
DESIGN TRENDS IN RECENT YEARS
Radial Short Circuit Stress
Short Circuit Stress in Core Type Transformers with
cylindrical windings
Internal sketch of Transformer
PLAN VIEW
ELEVATION VIEW
Types of Transformer Tank
1) Conventional Tank
- Bolted Tank
- Welded Tank
2) Bell Type
Conventional Tank
Tank Cover
Turret
Tank
Body
Stiffner
Core Clamping structure
Resiglass
Tape

Clamp Plate
End
Frame
Leakage Flux
Flux entering the tank
Flux enters the Shunt
Clearance between Windings and Yoke
Angle rings and Caps with Field
Fittings and Accessories
Buchholz Relay
conservator
Breather
Magnetic Oil Level gauge
Winding Temperature Indicator
Oil Temperature Indicator
Fans
Radiators
Pressure relief Device
Thermometer
Oil Preservation System

Marshalling Box
Bushings
Post Insulator
Current Transformer
On Load Tap Changer

Oil Preservation System
Breather
Air cell
Typical Outline General Arrangement
.

V
V 1
.V
+ V
1
.1
A: ELEVATION
V
.
.V
.

V
^V-
1

.1
1
B: PLAN
Thanks