This is the presentation on how transformer are manufactured in Areva factory , it gives detailed view of tranformers and uses too.

1. Manufacturing Of Transformer
&
It’s Accessories
Harshit Srivastava
Department Of Electrical And Electronics
Engineering
Fall Semester 2010
Roll No. 0705621028
29-08-2010
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2. INTRODUCTION
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)
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3. Topics
1. Introduction of Areva
2. Steps for manufacturing of
transformer
I. Overview of steps
II. Relationships between them
3. Uses of transformer
4. Accessories of Transformer
5. Steps done to solve issues in
industries
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4. AREVA T&D WITHIN THE GROUP
T&D: 1/3 of AREVA’s energy business
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Source: 2010 AREVA annual report
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5. COMPLETE PORTFOLIO
OF ELECTRICITY TRANSMISSION & DISTRIBUTION
Products
Power
Transformers
Generator Circuit
Breakers
Disconnectors
Instrument
Transformers
Primary Distribution
Gas-Insulated
Secondary Distribution
Substations
Circuit Breakers
Distribution
Transformers
Systems
Substations
Power Electronics
Distributed Energy
Power Distribution
Automation
Automation Products
Automation Systems
Automation Support
Service
Maintenance &
Repair
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Erection &
Commissioning
Retrofit
Spare Parts
Total Asset Care
Training & Network
Consulting
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6. PRODUCT LINE - POWER TRANSFORMER
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7. PTI - Technology
Worldwide Manufacturing Facilities
Stafford
United-Kingdom
Mönchengladbach
Germany
Jakarta
Indonesia
Le Petit-Quevilly
France
Saint-Ouen
France
Shanghai
China
Naini
India
Gebze
Turkey
Brisbane
Australia
Canoas
Brazil
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Power Transformer
March 2002- 7

8. Manufacturing Process
Of Transformer
RAW
MATERIAL
• 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
ASSEMBLY
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• 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.
• The coils as specified in the design may be
of following types:
• L.V COIL
• H.V COIL
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9. TESTING
TANKING
• COIL WINDING
• CONNECTION
• 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).
• ROUTINE TEST
• RATIO METER METHOD
• DIELECTRIC TESTS
TESTING AT • IMPULSE TEST LEVELS
POWER LEVEL • TEMPERATURE RISE TEST
DISMANTLIN
G&
DISPATCH
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• 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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10. RAW 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
CRGO
B (Telsa)
 27M-4
0.83
1.22
 MOH
0.72
0.99
 ZH100
0.70
0.96
 ZDKH90
0.60
0.83
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CTC (Continuous Transposed
Conductors) 10

11. CORE CUTTING
E shape
I shape
V shape
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12. COIL WINDING
HELICAL WINDING
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CONTINUOUS DISC WINDING
SPIRAL WINDING
INTERLEAVED DISC WINDING
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13. CORE FITTING
 CONSTRUCTION
1.THREE LEG (NORMAL)
2.FIVE LEG (TO REDUCE HEIGHT)
 CLAMPING ARRANGEMENT
1.END FRAME & INSULATION
2.CLAMPING PLATES
3.YOKE BOLTS
OR
YOKE STEEL BAND
(NO HOLE PUNCHING REQ )
 PROPER TIGHTENING TO REDUCE NOISE
LEVEL
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 VARNISH AT EXPOSED SURFACES
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14. The steps are being continued..
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15. 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 CORRECTNESS
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16. TESTING
CORE ASSEMBLY
COIL MANUFACTURING
TYPES OF TESTS
 STAGE TESTING ( DURING
MANUFACTURING STAGE)
 ROUTINE TEST
AFTER TG STAGE
DRYING & PROCESSING
 TYPE TEST
FINAL SERVICING
 SPECIAL TEST
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FINAL TANKING,OIL FILLING
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17. TANKING
Oil filling station where tanking is done
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18. DISMANTLING & DISPATCH
Shipping list
Commissioning
Physical inspection of tank before placing it
Onto trailor
Final inspection for traveling point of view
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19. PRECAUTION & GENERAL PRACTICES
IN COIL
ADOPTED
• PRECAUTION
Conductors with rounded of
edge
Strip & spacers shouldn't
have sharp edges
Clean winding & insulation
shop
• STABILISATION OF
WINDINGS
Alignment
2 to 3 heating cycle &
pressing under hydraulic
press
HYDRAULIC PRESS FOR COIL
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20. POWER MARKET
Estimated capacity shortfall in GW
5-10 x Scale-up REQUIRED IN RATE OF
CAPACITY ADDITION
Annual Capacity Addition in GW / year
Source: Powering India – Road to 2017, McKinsey 2008
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If business as usual
continues…India is likely to
face a capacity shortfall of 95140 GW by 2017
Source: Powering India – Road to 2017, McKinsey 2008
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21. TECHNOLOGY REQUIREMENTS
 ULTRA MEGA POWER PROJECTS- LARGE GENERATOR
TRANSFORMER -936 MVA
 POWERGRID AS MAIN NODAL AGENCY
 FORMATION OF CENTERAL GRID
 INTERCONNECTION OF GRIDS
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22. TECHNOLOGY CHALLENGES
 765kV System & Network
 800kV HVDC Transmission
 1200kV Development System
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23. USES
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.
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