Manufacturing Of Transformer & It’s Accessories Harshit Srivastava Department Of Electrical And Electronics Engineering Fall Semester 2010 Roll No. 0705621028 29-08-2010 1
Areva "Manufacturing of transformer, uses & it’s accessories"
Nov 04, 2014
This is the presentation on how transformer are manufactured in Areva factory , it gives detailed view of tranformers and uses too.
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Manufacturing Of Transformer&
It’s Accessories
Harshit SrivastavaDepartment Of Electrical And Electronics Engineering
Fall Semester 2010Roll No. 0705621028
29-08-2010
2
This presentation is an overview of some of the ideas and techniques used by Areva T&D Ltd. In developing transformers.In Areva the transformer development department is mainly divided into 3 categories:1. Power Transformer ( P.T)2. Medium Power Transformer (M.P.T)3. Distributed Transformer (D.T)
INTRODUCTIONINTRODUCTION
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1. Introduction of Areva2. Steps for manufacturing of
transformerI. Overview of stepsII. Relationships between them
3. Uses of transformer4. Accessories of Transformer5. Steps done to solve issues in
industries
TopicsTopics
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4Source: 2010 AREVA annual report
T&D: 1/3 of AREVA’s energy business
AREVA T&D WITHIN THE GROUPAREVA T&D WITHIN THE GROUP
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Products
Circuit BreakersGenerator Circuit Breakers
Disconnectors
Gas-InsulatedInstrument TransformersPower
Transformers
Primary Distribution Secondary Distribution Distribution Transformers
Systems
Substations Power Electronics Distributed Energy Power Distribution
Automation
Automation SupportAutomation Products Automation Systems
Service
Maintenance & Repair Total Asset Care
Erection & Commissioning Retrofit Spare Parts Training & Network
Consulting
COMPLETE PORTFOLIO OF ELECTRICITY TRANSMISSION & DISTRIBUTION
COMPLETE PORTFOLIO OF ELECTRICITY TRANSMISSION & DISTRIBUTION
Substations
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629-08-2010
PRODUCT LINE - POWER TRANSFORMERPRODUCT LINE - POWER TRANSFORMER
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CanoasBrazil
MönchengladbachGermany
ShanghaiChina
GebzeTurkey
NainiIndia
Le Petit-QuevillyFrance
Saint-OuenFrance
StaffordUnited-Kingdom
JakartaIndonesia
BrisbaneAustralia
March 2002- 7
PTI - Technology
Power Transformer29-08-2010
Worldwide Manufacturing FacilitiesWorldwide Manufacturing Facilities
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RAW MATERIA
L
• Raw material basically used is CRGO(cold rolled grained oriented)silicon steel.
• The purpose of using CRGO is to reduce the Hysteresis Losses.
CORE CUTTING
• 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.
COIL WINDING
• Coil Winding is of two types:-• R-S COIL • HELICAL COIL • SPIRAL COIL
CORE
FITTING
• 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.
Manufacturing Process Of Transformer
Manufacturing Process Of Transformer
ASSEMBLY
• The coils as specified in the design may be of following types:• L.V COIL• H.V COIL
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TESTING
• COIL WINDING• CONNECTION
TANKING
• Tanking is a procedure of embracement of complete unit (active unit) in a mild steel tank, the unit being enclosed includes (core entrapped with windings).
TESTING AT
POWER
LEVEL
• ROUTINE TEST• RATIO METER METHOD• DIELECTRIC TESTS • IMPULSE TEST LEVELS• TEMPERATURE RISE TEST
DISMANTLING &
DISPATCH
• After testing is completed and before dispatch from the factory all necessary work, e.g. removal of bushings etc. shall be performed.
• A shipping list is made concerning the General arrangement drawing which list out the external attachments of a power transformer to be send to customers .
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RAW MATERIAL USEDRAW MATERIAL USED
MATERIAL- CRGO SILLICON STEEL
DIFFERENT GRADES OF CRGO
CTC-Continuous transposed material
TYPICAL LOSS VALUE (W/Kg) AT 50 Hz & B (Tesla)
GRADE LOSS VALUE B (Telsa)
27M-4 0.83 1.22
MOH 0.72 0.99
ZH100 0.70 0.96
ZDKH90 0.60 0.83
CRGO
CTC (Continuous Transposed Conductors)29-08-2010
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CORE CUTTINGCORE CUTTING
I shape
E shape
V shape
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COIL WINDINGCOIL WINDING
HELICAL WINDING SPIRAL WINDING
CONTINUOUS DISC WINDING INTERLEAVED DISC WINDING29-08-2010
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CORE FITTINGCORE FITTING
CONSTRUCTION
1.THREE LEG (NORMAL)2.FIVE LEG (TO REDUCE HEIGHT)
CLAMPING ARRANGEMENT
1.END FRAME & INSULATION2.CLAMPING PLATES3.YOKE BOLTS OR YOKE STEEL BAND
(NO HOLE PUNCHING REQ )
PROPER TIGHTENING TO REDUCE NOISE LEVEL
VARNISH AT EXPOSED SURFACES29-08-2010
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The steps are being continued..The steps are being continued..
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ASSEMBLY(BEFORE TERMINAL GEAR STAGE)
ASSEMBLY(BEFORE TERMINAL GEAR STAGE)
TOP YOKE REMOVAL
LEVELING OF BOTTOM SUPPORT BLOCK
LEG PREPARATION VISUAL CHECKING OF COIL
LOWERING OF COIL IN PROPER ORIENTATION
TOP INSULATION & CLAMPING RINGS
MOUNTING OF ENDFRAMES
SHRINKAGE IN HEATER
TOP YOKE FITTING
BTG TEST FOR CHECKING CORRECTNESS29-08-2010
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TYPES OF TESTS
STAGE TESTING ( DURING MANUFACTURING STAGE)
ROUTINE TEST
TYPE TEST
SPECIAL TEST
TESTINGTESTING
CORE ASSEMBLY COIL MANUFACTURING
AFTER TG STAGE
DRYING & PROCESSING
FINAL SERVICING
FINAL TANKING,OIL FILLING29-08-2010
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TANKINGTANKING
Oil filling station where tanking is done
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DISMANTLING & DISPATCHDISMANTLING & DISPATCH
Shipping list
Commissioning
Physical inspection of tank before placing it
Onto trailor
Final inspection for traveling point of view
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IN COIL • PRECAUTION
Conductors with rounded of edgeStrip & spacers shouldn't have sharp edgesClean winding & insulation shop
• STABILISATION OF WINDINGSAlignment2 to 3 heating cycle & pressing under hydraulic press HYDRAULIC PRESS FOR COIL
PRECAUTION & GENERAL PRACTICES ADOPTED
PRECAUTION & GENERAL PRACTICES ADOPTED
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5-10 x Scale-up REQUIRED IN RATE OF CAPACITY ADDITION
Source: Powering India – Road to 2017, McKinsey 2008
Annual Capacity Addition in GW / year
Source: Powering India – Road to 2017, McKinsey 2008
Estimated capacity shortfall in GW
If business as usual continues…India is likely to face a capacity shortfall of 95-140 GW by 2017
POWER MARKETPOWER MARKET
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ULTRA MEGA POWER PROJECTS- LARGE GENERATOR
TRANSFORMER -936 MVA
POWERGRID AS MAIN NODAL AGENCY
FORMATION OF CENTERAL GRID
INTERCONNECTION OF GRIDS
TECHNOLOGY REQUIREMENTSTECHNOLOGY REQUIREMENTS
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765kV System & Network
800kV HVDC Transmission
1200kV Development System
TECHNOLOGY CHALLENGESTECHNOLOGY CHALLENGES
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Uses
Power Transformers are used for a variety of reasons, but they all have one thing in common; namely that the power being received must be tailored for the specific use.
USESUSES
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THANK YOU
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