SUMMER TRAINING PRESENTATION

“CROMPTON GREAVES,MANDIDEEP”

“Smart Solutions , Strong Relationships”

 INTRODUCTION
 Crompton Greaves established in1878, by R.E.B. Crompton.
 The company merged with F.A Parkinson in the year 1927 to form
Crompton Parkinson Ltd., (CPL).
 It collaborate with GCC. In the year 1947.
 Today, Crompton Greaves (CG) is part of the Avantha Group.
 The new identity, Avantha, was launched worldwide on 15
November 2007.
 It Awarded for 2000-2001, by the Indian Institution of
Industrial Engineering, for successfully implementing his vision of
making Crompton Greaves a world-class manufacturing company.
 Power Transformer

Transformers with ratings above 5000KVA are used in

generating stations and sub- stations for stepping up or
stepping down the voltage are called power
transformers .These transformers are manipulated to
operate almost always at or near the rated capacity.
 Purpose of Power Transformer

The purpose of a power transformer is to transfer

efficiently and instantaneously from an external
electrical source to an external load.In doing so, the
transformer also provide important additional
capabilities such as
 The primary to secondary turns ratio can be established
to efficiently accommodate widely different input/output
voltage levels.
 Multiple secondary with different numbers of turns can
be used to achieve multiple outputs at different voltage
levels
 Classification of Power Transformer

 Generator transformers for thermal, nuclear, hydro and

gas generating stations.
 Up to 450-900MVA.
 Auto transformer for step up and step down.
 Reactors, series and shunt up to 80MVA.
 Multi winding auto and generator transformers
Crompton Greaves Consist mainly four divisions:-

 Quality
 Production
 Testing
 Dispatch
 Quality Check
Two major functions are performed
1) 103 Movement
The 103 Movement is performed when the stock is received at the
company gates, the material is checked against the list of the materials
ordered however no entry accounting is done at this moment, the
acknowledgment of the reception of the materials is done but its validity is
not communicated.
2) 105 Movement
The materials are then unloaded from the truck into the stores and the
quality assurance department checks whether the materials received are
of appropriate quality. During the 105 movement, the materials department
safely stores the materials received in the Stores with appropriate
utilization of the space available
 Quality check

 Quality is checked by two processes:-

1.Physically
In this , components are checked physically Ex :-there should be no cracks,
no impression , no damage of the component .

2)Dimensionally
In this, components are checked by precise instrument. Ex:-vernier caliper, meter
gauge etc. In this inspection we also control the temperature and moisture
.Before releasing an order, it ensures that the components are physically and
dimensionally correct, so periodic checking of actual inventory status and the one
available in the system is necessary.
In any discrepancy, the few people can be deployed in checking
inventory from time to time. Any correction may be entered in the system and the
process continues till the discrepancy disappears.
Design of Transformer
There are mainly three branches involved in design of
transformer. All the three worked in a co-ordinated
manner thus complimenting each other in order to
accomplish the task . The three branches are:-
i) Electrical
ii) Mechanical
iii) Control
i)Electrical

Electrical section takes care of the design and the

windings and arrangements of insulations. The design
procedure consists of preparing an electrical
specification sheet and an insulation arrangement
drawing, along with a bill of materials(BOM).The task of
core cutting is also based on data from the above
specifications .The most important job of cooling is also
taken care of by electrical section. Finally the testing of
the transformer for various faults conditions is done by
the electrical division.
ii) Mechanical

The mechanical section comes into picture after the

designing part . The design of the tank, support
structures are looked after by mechanical section . In
short the core coil assembly is handled by them.
iii)Control

The control of transformer is of prime importance. It

provides control of the taps , oil and winding
temperature etc . Remote tap changer controller
(RTCC) provides remote tap changing ability. Oil
temperature indicator(OTI) and winding temperature
indicator(WTI) Keep a check on oil and winding
temperature respectively . Magnetic oil gauge (MOG)
shows the level of oil present in the transformer.
 Process Chart
Winding Coil clamping Coil Assembly Core Building

Core Coil Assembly

[ Auto Clave]

Connection

Vapour Phase
Drying

Servicing

Dispatch Painting Testing Tanking

 Winding
Winding is of two types:-
1.High Voltage Coils:
 A solid cylindrical former of predetermined diameter and length is being used as has
over which is made.
 Generally round insulated wire of either copper (Cu) or Aluminium (Al) is used as
basic raw material.
 The coils are made in number of layer.
 These leads are properly sleeved and locked at number of points.
2.Low Voltage Coils:
 L.V. Coils are also one of the components of transformer. The procedure of making
low voltage coil is generally same as above.
 The shape of the basic raw-material (Al or Cu) is rectangular
Diagram of Winding
Coil Assembly
 The basic raw-material is COLD ROLLED GRAIN ORIENTED
(CRGO) Silicon Steel
 It is in the form of thin sheets & cut to size as per design.
 Generally three different shapes of core laminations are used in
one assembly.
 Notching is performed to increase the magnetic path.
 The laminations are put through annealing process.
 These laminations are assembled in such a manner that there is
no air gap between the joints of two consecutive sheets.
 The entire assembly is done on a frame commonly known as core
channel. These frames being used as a clamping support of the
core assembly
Diagram of Coil Assembly
Core Building an Insulation

It provides the permanent support for insulation and coil

assembly.
 Insulation

Insulation materials are used to provide an electrical

insulation between parts at different potentials.It
reduces short circuit.Mostly used insulators are:-

plywood,rubber,plastic,wraps,spacers,blocks,pcb(preco
mpressed board) etc.
Types of insulation:-
i)Main insulation
ii)End insulation
 Properties of Ideal Insulating Material

 High insulation resistance

 High dielectric strength
 Low dielectric Losse and low dielectric loss angle
 No attraction for moisture
 Good heat conductivity
 High mechanical strength to withstand vibration and
winding
Diagram of Insulation
 Auto Clave
 A strong, pressurized, steam-heated vessel, as for
laboratory experiments or sterilization.
 Autoclaves use to increase the efficiency and
performance of any plant.This equipment comprises a
vacuum in which a cylinder containing a piston is
situated at one end and can be closed at the end by a
hollow piston containing a condenser casing. The
cylinder is evacuated through a port and the piston is
lowered to close the port immediately an injection valve
is opened to fill the cylinder with an impregnating
substance.
Core Coil Assembly
 The components produced in the coil winding and core assembly
stage are then taken into core-coil assembly stage.
 The core assembly is vertically placed with the foot plate touching
the ground. the top yoke of the core is removed. The limbs of the
core are tightly wrapped with cotton tape and then varnished.
 Cylinder made out of insulating press board/ pressphan paper is
wrapped on all the three limbs.
 Low Voltage Coil is placed on the insulated core limbs.
 Insulating block of specified thickness and number are placed both
at the top and bottom of the L.V.Coil.
 Cylinder made out of corrugated paper or plain cylinder with oil
ducts are provided over L.V.Coil.
 H.V. Coils are placed over the cylinder.
 Gap between each section of H.V. Coils including top & bottom
clearances is maintained with the help of oil ducts, as per the
design/drawings.
 The Top Yoke is refilled. Top core frame including core bolts and tie
rods are fixed in position.
 Primary and secondary windings are connected as per the
requirements. Phase barrier between H.V. phases are placed as
per requirement.
 Connections to the tapping switch (if required) are made.
 Finally, the component is placed in the oven.
Diagram of Core Coil Assembly
Vapour Phase Drying
 Drying of a utilized power transformer is an object that has been
worked on for many years.
 The main problem is to achieve an optimal drying of an aged
power transformer without the displacement to a
workshop, as this operation is very cost intensive and sometimes
no longer possible.
 Over 40 power transformers with a power of up to 400 MVA were
dried successfully on site.
 Tanking

All tanks are made of high quality steel and can

withstand vacuum as specified by the international
standards and the customer. All welds are tested,
ensuring 100% leak proof of seems and mechanical
strength. Transformer with Corrugated Fin-Type
radiators can also be supplied. The fins are
manufactured of Gold-rolled steel. The fin height and
length are according to customer's specifications and
fins can be plain or embossed. All transformer tanks are
given a smooth finishing by using the "SHOT BLASTING
 Fittings like drain valves, HV& LV Bushings,
conservator, oil level indicator and explosion vent are
fitted in the tanks.
 The Core-coil assembly is then placed into the tank and
properly locked up.
 Pure filtered transformer oil is filled in the tank to
immerse the assembly only.
 Connections of primary and secondary to the terminal
bushings are made. Operating handle for ratio switch is
fitted, wherever required.
Diagram of Tanking
Temperature Rise Limit

In consumer or industrial applications a Transformer

temp. rise of 40०C-50०C may be acceptable,
reassuring in a maximum internal temperature
100०C. However, it may be wiser to use the next
size large core to obtain reduce temperature rise
and reduced losses for better power supply
efficiency.
 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 are several tests that can be done on the transformer.
Method of Testing
This is nothing but the resistance measurement of the windings by
applying a small
d.c voltage to the winding and measuring the current through the
same. The ratio gives
the winding resistance, more commonly feasible with high voltage
rise of the transformer is required, then test method is the most
dependable one. There windings. For low voltage
windings a resistance-bridge method can be used. From the d.c
resistance one can get the
a.c. resistance by applying skin effect corrections.
 Painting
The entire procedure of painting is done under two stages:
Cleaning of tanks
 The cleaning of tank is done normally by chipping/grinding.
 The outside surface of the tank is short blasted to achieve a very
fine and smooth finish
Painting of tanks
 After cleaning the tanks, a coat of hot oil resistance paint is applied
on the internal surface of the tank.
 The outside surface is painted with a coat of Red Oxide primer and
subsequently with one coat of enamel paint as per customer's
requirement.
 Separate primary and secondary winding facilitate high
voltage input/output isolation , especially important for
safety in off-line applications.
 Losses
Transformer loss is some times limited directly by the
need to achieve required over all power supply
efficiency . More often, transformer losses are limited
by a maximum ” Hot Spot”. Temperature at the core
surface in side the centre of the windings.
1)Worst case losses
2)Winding losses
 1.Worst case losses
Transformer losses should be examined under worse
case conditions that the power supply expected to
operate over long periods of time , not under transient
conditions Transformer losses can be put into three
major categories:-
i)Core hysteresis losses
ii)Core eddy current losses
i)Core hysteresis losses:-It is a function of flux swing and
frequency . In all buck –derived applications under
steady state conditions. Hysteresis is constant,
regardless of changes in voltage(Vin) or load current.
ii)Core eddy current losses:-It is really I²R loss in the
core material. If Vin doubles , peak I²R loss
quadruples , core eddy current loss is proportional
to Vin. Worst case is at high Vin.
 2.Winding loss

Peak secondary current equals load current and peak

primary current equals load current divided by the turns
ratio . Peak currents are independent of Vin . But a
constant peak currents (constant load),r.m.s current
squared(and I²R loss) is proportional to duty cycle
D and inversely proportional to Vin.
 Finishing

 Fittings and accessories as per customer's specification

and drawing are checked.
 Air Pressure test is subjected to avoid any leakage and
seepage on all transformer.
 Transformers are filled with oil upto the minimum level
marking, wherever necessary.
 Loose accessories like, earthing terminals, bimetallic
connectors, dial type thermometers are also checked
for proper fittings.
Conclusion

I was given the opportunity to do my summer

internship project in the CG which is the largest
transformer manufacturing enterprise . To conclude this
project report I can say that the company holds a good ,
market share and is managing well even when there is
a big competition . market in front of CG study proves
that the company has entered into the technical
collaboration with many international firms through
acquisitions Where , the competition is increasing day
by day like this Crompton Greaves is hanging its
working style in performance and providing after sales .
services to the customer.
 Suggestion

Insulation arrangements for the 132 kV class power

transformer was standardized with 220 kV class as
reference. The accomplishment of the project has
enabled the design engineers to reduce the time
preparation of bill of materials(BOM)from 4 to 6 hrs.
 
 
 
THANK YOU
 REPRESENTED BY:-
 KANHAIYA KUMAR &
 RANVIJAY KUMAR SINGH
(JAI NARAIN COLLEGE OF TECHNOLOGY,BHOPAL)