TRANSFORMERS SECOND EDITION we “ja Bharat tT Electricals LimitedInformation contained in this work has been obtained by Tata McGraw-Hill, from sources believed to be reliable. However, neither Tata McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein, and neither Tata McGraw-Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that Tata McGraw- Hill and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. Tata McGraw-Hill Copyright © 2003, 1987, Bharat Heavy Electricals Limited, Piplani, Bhopal, MP Sixth reprint 2008 RZCLCDLYDRDAX No part of this publication may be reproduced or distributed in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise or stored in a database or retrieval system without the prior written permission of the publishers. The program listings (if any) may be entered, stored and executed in a computer system, but they may not be reproduced for publication. This edition can be exported from India only by the publishers, Tata McGraw-Hill Publishing Company Limited. ISBN-. ISBN- : 978-0-07-0483 15-6 }: 0-07-0483 15-9 Published by the Tata McGraw-Hill Publishing Company Limited, 7 West Patel Nagar, New Delhi 110 008, typeset in Century Schoolbook at Tej Composers, WZ 391, Madipur, New Dethi 110 063, and printed at Sai Printo Pack P. Ltd., Okhla Indl Area, New DelhiContents Message I vii Message II ix Foreword xi Preface to the Second Edition xiii Preface to the First Edition xv Acknowledgemenis xvii Editorial Committee xviii 1_Introduction CS © T.K. Ganguli 2. Principles of Transformers 6 ® RK. Singh 2.1 Working Principle of a Transformer 6 2.2 Elementary Theory of an Ideal Transformer 7 2.3 EMF Equation ofaTransformer 8 2.4 Voltage Transformation Ratio(K) 9 2.5 Ideal Transformer 10 2.6 Transformer Having Winding Resistance But No Magnetic Leakage 13 2.7 Magnetic Leakage 14 Leakage Reactance 15 2.9 Equivalent Circuit 16 2.10 Regulation 27 2.11 Losses in Transformers 21 2.12 Efficiency 22 2.13 The Auto-Transformer 23 2.14 Three-winding Transformer 25 2.15 Parallel Operations of Transformers 27 Appendix References 33xx Contents 3._Materials Used in Transformers SSA © M.P. Singh, T.K. Ganguli 3.1 InsulatingOil 34 3.2 InsulatingPaper 47 3.3 Presshoard 51 3.4 Wood 58 3.5 Insulated Copper Conductor forWindings 59 3.6 Crepe PaperCovered Flexible CopperCable 66 3.7 SealingMaterials 66 ‘CRGO) 68 3.9 Structural Steel 87 3.10 Future Trends 84 References 85 4, Magnetic Circuit 8 © K.N. Labh, R.C. Agarwal 4.1 Material 86 4.2 Design of Magnetic Circuit 87 4.3 Optimum DesignofCore 91 4.4 Manufacturing 99 References 107 5._Windings and Insulation 108 ® M.V. Prabhakar, S.K. Gupta 5.1 Types of Windings 108 5.2 Surge Voltage Behaviour of Windings 116 5.3 Internal Heat Transferin Windings 125 5.4 Insulation Design 126 5.5 Electric Field Plotting 130 5.6 Finite Difference Method(FDM) 131 References 136 6. Voltage Regulation and Tapchanger 138 © B.L. Rawat, A.K. Ekka 6.1 Off-circuitTapchanger 138 6.2 On-loadTapchanger(OLTC) 141 63 Constructional and Operational FeaturesofOLTC 148 6.4 Manual and Electrical Operation of Tapchanger 150 6.5 Automatic ControlofTapchanger 151 66 Tapchanger Selection 151 6.7 Latest Trends inTapchanger Design 152 Reference 153Contents xxi 7. Electromagnetic Forces in Power Transformers 154 © M.V. Prabhakar, T.-K. Ganguli 7.1 Leakage Flux in a Typical Two Winding Transformer 154 7.2 NatureofForces 154 7.3 Basic Formula and Methods for Force Evaluation 158 74 Radial Forces 159 7.5 AxialForces 160 7.6 Roth's Method of Force Calculation 163 7.7 Modes of Failure of Windings and Design ofWindings 166 7.8 Strengthening of Coils to Withstand Short-circuit Forces 168 79 Design of Clamping Structures 169 7.10 Listof Symbols 174 References 176 8. Cooling Arrangements 177 © C.M. Sharma 8.1 Various Types of Cooling 177 8.2 Cooling Arrangements 179 83 PropellerTypeFans 185 8.4 Transformer OilPump 188 8.5 FlowIndicators 190 86 Stress and HydraulicAnalysis of Pipework 191 9. Design Procedure 198 © RC. Agarwal 9.1 Specifications of aTransformer 198 92 Selection of Core Diameter 198 9.3 Selection of Flux Density 199 9.4 Selection of Type of Core 200 9.5 Selection of Leg Length 200 9.6 Selection of Type of Windings 201 9.7 Selection of Tapchanger 202 98 Calculation of Number of Turns 203 9.9 Selection of Conductor andCurrent Density 203 9.10 Insulation Design 204 ofCoils 204 9.12 Ampere-turnBalancing 205 9.13 ReactanceCaleulation 205 9.14 Iron Weight andLosses 210 9.15 Copper Weight and Losses 21010. ll. Contents 9.16 Stray Losses in Transformer 217 9.17 Stray Loss Control_214 9.18 Impulse Calculation 218 9.19 Mechanical ForcesinWindings 218 9.20 Temperature Gradient andCoolingCalculation 219 9.21 Typical Design Calculations for Two Winding and Auto-transformers 219 References 226 Structural Design of Transformer Tank 227 © M.K. Shakya, S.G. Bokade 10.1 Types of Tank Constructions 227 10.2 Structural Design of Transformer Tanks 230 10.3 TestingofTanks 244 References 250 Transformer Auxiliaries and Oil Preservation Systems 251 * S.C. Verma, J.S. Kuntia Transformer Auxiliaries 251 11.1 Gas Operated (Buchholz) Relay 251 11.2 TemperatureIndicators 253 11.3 Pressure ReliefValve 255 114 Oil Level Indicator 256 115 Bushing andCableSealingBox 257 Transformer Oil Preservation Systems 258 11.6 Silicagel Breather 260 11.7 Gas Sealed Conservators 260 11.8 Thermosyphon Filters 263 11.9 Bellows and Diaphragm SealedConservators 264 11.10 Refrigeration Breathers 265 12, Manufacturing and Assembly 267 © T.K. Ganguli, M.V. Prabhakar 12.1 Core Building 267 12.2 Preparation ofWindings 268 12.3 Winding Assembly 269 12.4 Coreand Winding Assembly 271 12.5 TerminalGearAssembly 271 12.6 Placement of Core and Winding Assembly in Tank 272 12.7 Processing 273 12.8 Servicing of Transformer 273 129 Tanking 274Contents xxiii 13. Drying and Impregnation © M.P. Singh, M.V. Prabhakar 13.1 Basic Principles of Drying 276 PrinciplesofDrying 277 13.2 Conventional Vacuum Drying 278 13.3 VapourPhase Drying 281 References 290 14. Testing of Transformers and Reactars © P.C. Mahajan, M.L. Jain, R.K. Tiwo SectionI 292 14.1 Testing of PowerTransformers 992 Section II 305 14.2 Impulse Testing 305 References 320 Section III 327 14.3 PartialDischargeTesting 321 References 334 SectionIV 335 14.4 Testing ofReactors 335 References 349 SectionV 350 14.5 Short Circuit Testing of Power Trar formers 350 15. Standards on Power Transformers © V.K. Lakhiani, S.K. Mahajan 15.1 First Revision of IS: 2026 359 15.2 Other Related Standards 364 15.3 NewStandards 367 15.4 Standard Specification ofaPowerTr. sformer 368 Appendices 372 16. Loading and Life of Transformers ° D.P. Gupta 16.1 Lifeofa Transformer 378 16.2 Ageing ofInsulation 379 16.3 LawofInsulationAgeing 381 16.4 Significance of Weighted Value of AmbientTemperature 384 16.5 Relationship between WeightedAmbir , Winding Rise andHot-spotTemperatu < 386 16.6 Determination of Weighted AmbientTemperature 394 16.7 Relationship between Weighted Ambient andLoad 399 275 291 358 377xxiv Contents 17. 19. 16.8 Alternative Approach for the Calculation ofWeightedAmbient 400 16.9 Transformer Loading Guides 407 16.10 Loading by Hot-Spot Temperature Measured by WTI 409 16.11 Selection and Use of aTransformer 411 References 413 Annexures 414 Erection and Commissioning 439 © C.M. Shrivastava 17.1 Despatch 439 17.2 Inspection upon Arrival atSite 440 17.3 Handling 440 17.4 Installation 441 17.5 Commissioning 447 17.6 Maintenance 449 17.7 Dos for Power Transformer 451 17.8 Don'ts for Power Transformers 453 17.9 Dosand Don’ts for HVCondenser Bushings 454 Transformer Protection 456 © BL. Rawat 18.1 Protection against ExternalFaults 456 18.2 Protection against InternalFaults 459 References 465 Reactors 466 * C.M. Shrivastava, S.K. Mahajan 19.1 SeriesReactors 466 19.2 Shunt Reactor 473 19.3 Neutral Earthing Reactor 482 19.4 Tuning for FilterReactors 482 19.5 ArcSuppressionReactors 483 19.6 EarthingTransformers (NeutralCouplers) 483 19.7 Standardson Reactors 484 . Traction Transformers 486 © J.M. Malik 20.1 Types ofTraction Transformers 486 20.2 Special Considerations 487 20.3 Design and Constructional Features 489 20.4 Traction Transformer for Thyristor Controlled Locomotives 493 References 495Contents xxv 21. Rectifier Transformers 496 e JS. Sastry 21.1 Comparison between Rectifier Transformer andPower Transformer 497 21.2 RectifierCircuits 499 21.3 Design Features of Rectifier Transformers 503 21.4 Transductors 517 21.5 Constructional Features of RectifierTransformers 518 21.6 Tank Design 52] 21.7 Testing 523 References 525 22. Convertor Transformers for HVDC Systems 526 ® .C. Tayal, C.M. Sharma, S.C. Bhageria 22.1 Insulation Design 526 22.2 Higher HarmonicCurrents 529 22.3 DCMagnetization 529 22.4 DC Bushings 530 22.5 OnLoad Tapchanger 530 22.6 Influence ofImpedance Variation 530 22.7 Connections 531 22.8 Specifications 533 22.9 Manufacturing Features 533 22.10 Tests 536 References 538 23. Controlled Shunt Reactor 539 © S.C. Bhageria, J.S. Kuntia 23.1 Controlled Shunt Reactor (CSR) Principle 539 23.2 Controlled Shunt Reactor Transformer(CSRT) 541 23.3 Special Features of the Controlled Shunt Reactor Transformer 545 23.4 Controlled Shunt Reactor Much More ThanaShunt Reactor 549 23.5 Conclusion 550 References 550 24, Designing and Manufacturing — A Short Cireuit Proof Transformer 551 © T.-K. Ganguli, S.K. Gupta 24.1 Forces During Short-Circuit 552 24.2 Various Considerations to Design a Transformer Suitable for Short-Circuit Duty 556 24.3 Manufacturing Aspects 559XXV1 Contents 24.4 Quality Aspects 560 24.5 Conclusion 560 High Voltage Condenser Bushings 562 © R.K. Agarwal, Assem Dhamija 25.1 Introduction 562 25.2 Classification of Bushings 562 25.3 DesignofBushing 565 25.4 Constructional Details and Main Parts ofBushing 567 25.5 TestingofBushing 571 25.6 Factors Affecting the Performance ofBushing 573 25.7 Condition Monitoring at Site 574 25.8 Dos and Don'ts for HV Condenser Bushings 575 Computerisation—A Tool to Enhance Engineering Productivity 577 © R. Mitra, DEM/TRE . Condition Monitoring, Residual Life Assessment and Refurbishment of Transformers 581 ° CM. Shrivastava, T.S.R. Murthy SectionA 581 27.1 AnalysisMethod 582 27.2 Physical Inspection 584 27.3 Residual Life Assessment(RLA) 588 27.4 Different Techniques for Life Estimation 589 27.5 Methodology Adopted 591 27.6 Conventional and Special Tests on OilSamples 592 27.7 Refurbishment 593 27.8 Conclusion 596 AnnexureI 597 28. Transformers: An Overview 598 © S.N. Roy, P.T. Deo Solved Examples 603 Index 609RC This book covers all the aspects of power BCU Osteo m Olena Me Mt Smet ne principles, manufacturing technology, materials specifications and standards. It also covers special transformers, including reactors and converter transformers for HVDC systems. BRET m ey area LrseM solceltTs tlhe DSCC LGU tarre eerie SCC oR acs Clg * Short-circuit testing of transformers Sa SLCSUN NSM Oba cress oan(ced SEE EUR Casha But tin Corrects Pecuosu tice AFT Neto hes RT book will serve as an excellent reference book for practising engineers ‘engaged in the design, manufacture, planning, Lee Mo cclas Oo MM LaO MEL MBA ET cat acme a transformers. It will also be useful to students and Pa ee =m | {G0 Bharat Heavy Electricals Limited is the largest engineering an iT) pCi CCo abe cgeec RS en C RUMOR NCB CRMs a MET Itt pe soe nee Caen tan tN catty The first plant of BHEL was set up at Bhopal in 1956, and ers wie e ciety services extend from project feasibility studies to after-sales service, success: meeting diverse needs through turnkey capability. The dale Taya ce Coe pre Cade lle moto Wo Coaica ola realacl Kec sccm ad technic cient iT: pea O Ma CC RM e EEG CeCe \ 0: 4335-9 Tata McGraw-Hill i | | si7acc7oMvaarsyl | ere