FEDERAL POWER TRANSFORMERS LLC (FPT).
(A ZUBAIR ELECTRIC GROUP COMPANY)
ICAD 1, MUSSAFAH, P.O Box 111209,
Abu Dhabi, United Arab Emirates.
Tel : +971 2 550 1910
Email : sales@[Link]
Website : [Link]
ZUBAIR ELECTRIC GROUP
Our KSA business is looked after by.
SPECTRA INTERNATIONAL TRADING COMPANY.
(A ZUBAIR ELECTRIC GROUP COMPANY)
ABOUT US
• Federal Power Transformers LLC (FPT) and is a unit of Federal Electric
under ZUBAIR ELECTRIC GROUP.
• Federal Power Transformers LLC (FPT) is an ISO 9001:2015 Company
established in 2006 with dedicated art of the state facility at ICAD1 –
Abu Dhabi, for the manufacture of quality power transformers.
• FPT manufactures a range of power transformers up to 100 MVA,
132kV class.
• We have a comprehensive repair facility for refurbishment of
transformers and overhaul of tap changers.
• We have an innovative R&D team with highly advanced
manufacturing system ensures that the products meet the needs of
today’s market by combining the latest technology with reliability
and cost-effectiveness.
• The products are designed, manufactured & tested to comply with
various international standards.
• The plant has a dust free, air-conditioned environment and employs
state-of-the-art technology.
What We Offer.
• Power Transformers - Oil Filled Power Transformers ranging
from 5MVA to 100 MVA, 11KV to 132KV voltage Class.
• Oil and Gas Transformers – Transformers suitable for
hazardous area such as Oil and Gas fields suitable for Zone1
and Zone2 as per ATEX or IEC Ex.
• Renewable Energy Transformers – Transformers suitable for
Solar Load Profile and meeting technical requirements of
Invertor manufactures, Voltage ratings of 3.3 kV to 33 kV.
• Special Transformers, Mobile Substation Transformers, Cast
Resin Dry Type Transformers etc.
What We Have.
• Highly Innovative &
Experienced Design Team.
• Most advanced Software's
for R & D.
• World Class Facility for
Winding, Core and
Accessories
Manufacturing.
• Transformer Assembling
and Oil Processing.
• State of the Art Testing
Lab with most Modern
Apparatus.
• Well Qualified and
Experience Team of
Engineers.
TRAINING
on
TRANSFORMER.
Objectives of this training.
• To familiarize with the transformer.
• To familiarize with the transformer Operation.
• To familiarize with the transformer Accessories, etc.
The importance of transformer in a power
system.
• Transformers are one of the most important and expensive
pieces of equipment required for operating a power system.
• The purchase, preparation, assembly, operation and
maintenance of transformers represent a large expense to the
power system.
Why we need transformer ?
• We need transformer because, when current travels certain
distance, it looses some energy in form of heat... so in order
to preserve it is used for step-up and step-down function....
• Also to step-up and step-down the voltages to required levels.
Transformer
Construction
Construction of Transformer.
1. Laminated Core
2. LV Winding
3. HV Winding
4. Tap Winding
5. Tap Changers
6. Bushings
7. Tank
8. Conservator
1. Laminated Core
• Core provides low reluctance path for Magnetic Flux.
• Through the core, Power is transferred from one circuit to
another.
• Core is made up of thin sheaths of CRGO with silicon content.
• Mitered joints are used in core construction to avoid losses.
• No Load Loss is guaranteed for every transformer.
[Link] Winding.
• Winding which connected to the Low Voltage.
• Normally this will be Cylindrical Helical Winding.
• As compared with other windings, Area will be more as the LV
side current is high.
• Fewer number of turns as compared with other windings.
• Normally innermost winding.
• Made of Multi stranded Continuously Transposed Conductor.
[Link] Winding.
• Winding which connected to the High Voltage.
• Normally this will be Disc Type Winding.
• As compared with other windings, Area will be less as the HV
side current is less as compared with LV.
• Larger number of turns as compared with other windings.
• Normally comes in between LV and Tap winding.
• Made of Single or Double stranded Conductor.
• Normally Tap winding also will be part of HV winding.
3. Tap Winding.
• Tap winding of transformer electrically connected HV winding
of the transformer.
• This winding has fewer number of turns than other two
winding and number of turns in tap winding depends on the
tap range of the transformer.
• From the tap windings output leads are taken at regular
intervals and connected to OLTC.
• Number turns added or subtracted from the circuit according
to the OLTC operation.
5. Tap Changers.
• Tap Changers are the devices which is used to increase or
decrease secondary side voltage by changing the turns ratio
of primary or secondary side.
• Tap Changers normally connected to High Voltage side of the
transformer.
• Tap leads of tap windings are connected to the tap changer.
• There are two types of Tap Changers,
A. On Load Tap Changer (OLTC)
B. Off-Load/No-Load Tap Changer (OCTC/NLC)
A. On Load Tap Changer (OLTC).
• Tap Changers are the devices which is used to
increase or decrease secondary side voltage by
changing the turns ratio of primary or secondary side
without interrupting the load current.
• It has following parts,
1. Motor drive unit
2. Tap selector
2. Divertor switch
3. Transition resistor
1. Motor Drive Unit (MDU)
• It provides driving for the operation of
Tap selector and Divertor switch.
• MDU includes a three phase motor,
gear mechanism and its control
circuits.
• It provides signal for tap raising and
lowering operations.
• All the parts enclosed in a cubicle and
mounted on the transformer.
• MDU provides drive through a shaft
and bevel gear arrangement.
2. Tap Selector (TS).
• Tap selector is the point where the
tap winding leads are connected.
• This part of OLTC is inside the main
tank of transformer and immersed
in the main tank oil.
• Tap selector operates on off load
condition.
• In every TS, Odd and Even tap leads
where separately connected.
3. Divertor Switch (DS).
• This is the part of Tap changer, where on
load switching takes place.
• DS assembly is kept in an separate tank
filled with oil and isolated from the main
tank.
• It has a fixing and moving contact.
• One set fixed contact is connected odd side
collector of TS and other set to even side
collector of TS.
• Moving contact switches between odd and
even fixed contact according to the MDU
signal.
• DS operation is through the discharge of
spring mechanism to ensure fast operation.
• DS chamber is connected to OLTC
conservator.
4. Transition Resistor.
• Transition resistors are the high value
current limiting resistors inserted
between the fixed contacts of
Divertor switch.
• This limits the momentarily short
circuit current during the switching of
DS.
• There are resistor based and
reactance based current control
method is employed in various OLTC.
Working of OLTC.
B. Off-Load/No-Load Tap Changer (OCTC/NLC)
• Tap Changers are the devices which is
used to increase or decrease secondary
side voltage by changing the turns ratio of
primary or secondary side in off load
condition.
• It has following parts,
1. Driving system- May be handle or
some time motor unit.
2. Tap selector
6. Bushing.
• Bushing are the most essential
component of transformer.
• It connects the winding leads to
external circuit with ingress and
leak proof sealing.
• It provides insulation between live
conductor metallic body at ground
potential.
• For distribution transformers, we
use mainly communicating type
bushings.
• The inside conductor should be
suitable as per rating of
transformer
• Every bushing is tested for its voltage withstand
capability and current carrying capacity as per SEC
requirement.
7. Transformer Tank.
• Transformer tank is made of Mild
Steel Plates.
• It provides housing for the winding,
core and the oil.
• Transformer tank is made such that
its capable of withstanding the high
pressure and electrostatic forces that
develop on the transformer.
• Other parts of transformer such as
Conservator, Radiator, Cable boxes,
Bushings, Cubicles etc mounted on
transformer tank.
8. Conservator
• Conservator is for the preservation of
transformer oil.
• During heating cycle of the
transformer oil will flow to the
conservator due to expansion
• During cooling cycle, the oil will flow
from the conservator to main tank.
• Conservator is provided with flexible
seperator and breather arrangement.
Transformer
Maintenance
Maintenance of Transformer.
• Transformer is the heart of any power system.
• Any failure to the transformer can extremely affect the whole
functioning of the system.
• Hence preventive maintenance is always cost effective and
time saving.
• As the transformer is a costly, complex piece of equipment
works on high voltage, preventive maintenance includes only
the regular and routine external maintenance of the asset to
any costly unplanned downtime from unexpected equipment
failure.
• Any abnormal or serious observations should be brought to
the notice of OEM and precise advice should be taken fore
any maintenance works on of transformer.
Routine inspection of transformer.
• Routine inspection of transformer can be carried out on daily
basis or monthly basis without any interruption to the
working of transformer and by an observer at Ground Level.
• The observations should be properly tabulated and kept for
reference.
• The following are the important routine inspection points.
1. Temperature indicator.
• Observe the readings of Oil Temperature Indicator and
Winding Temperature Indicator for any abnormal pattern. It
should be continuously monitored especially when the
transformer is being heavily loaded.
• Record the reading of maximum indicating pointer of both
OTI and WTI on daily basis.
• If any abnormal observations are noted, ensure the meter
sensing bulb is properly in position and its well is having oil.
• Ensure that any capillary tubes are free from kinks.
2. Oil level indicators.
• Observe the oil level in the magnetic oil level gauges provided
on the Main conservator and OLTC Conservator.
• Compare the oil levels with the cold oil level marked on the
MOLG.
• The Oil level will increase with temperature rise of oil and will
drop with diminishing temperature.
• If the oil level is low, new oil should be added to bring the oil
to the correct required level.
3. Gas operated relay.
• Observe the Buchholz Relay for any gas trapping through its
glass window.
• Presence any gas trapping in the glass window may be
indicative of a fault condition. It should be siphoned off
through the gas test cock of the relay and analyzed.
• If the gas trapping on the relay is repeated, the oil should be
analyzed.
4. Maintenance free breather.
• Transformer is provided with Maintenance free breather for
bot the main tank and OLTC side conservator.
• This type of breather is capable of re generate the silica gel
according to its saturation.
• The regeneration function should be monitored.
5. Oil leakage.
• Check for any signs of oil leakage from welded seams,
radiators & its plugs, flanges, plugs, bosses and valve outlets.
• Any signs of oil, that part should be tighten up the flange
bolts or screw down valve in question.
• The suspected part should be cleaned to remove the oil and
dirt and observe for any future symptoms.
• If needed, toping up oil is to be done only after the suspected
oil leak is cleared.
Annual inspection of transformer.
• Annual inspection of transformer is carried out after
isolating the transformer.
• The safety aspects of the men working should be
considered.
• The observations should be properly tabulated and kept
for reference.
• The following are the important annual inspection
points.
1. Transformer.
• Clean the transformer tank top to bottom and its fitting from
dirt and other deposits.
• Check the transformer tank and its fitting for any signs of rust
formation, especially on welded parts.
• If any rust formation is noted completely remove it with a
wire brush paint with a coat of zinc phosphate primer paint,
followed by an appropriate under coat and finally the
finishing coat.
2. Temperature indicators.
• Other than the routine inspection,
• Check the operation of micro switches.
• Adjust the micro switches, if needed.
• In every three years, check the accuracy of temperature
indicators, Recommendation only.
3. Oil level indicators.
• Other than the routine inspection,
• Check the working of MOLG, if any abnormalities noticed,
check its operation.
• Check the alarm and trip operation of gauge by lowering the
oil level in the conservator.
4. Gas operated relay.
• Other than the routine inspection,
• Check the working of alarm and trip signal by manually
pressing the test button.
• Physically inspect the Buchholz relay, for any damage.
• Check the alarm and trip switches operation by draining the
oil from Buchholz relay drain plug.
• Shut down the Buchholz relay isolating valve and conservator
isolating valve should be closed prior to draining oil.
5. Valves and gasketed joints.
• Ensure that the valves are closed/opened as per the OEMs
instruction provided on the valve schedule plate of the
transformer.
• Ensure the tightness of all gasketed joints.
• If retightening is needed, ensure the torque setting as per
OEMs recommendation.
6. Terminal connections.
• Ensure the tightness of all electrical bolted connections
including the cable box.
• Check the bushing mounting nuts for tightness to specified
torque settings.
• Inspect the bushing stem for oil leaks.
• Check the bushing palm are clean and intact.
• Check all the lead supports, ensure that there is no
mechanical strain on the transformer terminals.
7. Test on transformer oil.
• Sample the transformer oil from main tank and OLTC.
• Conduct the routine test on the oil sample for Moisture
content, Break Down Voltage and DGA.
• The result should be analyzed and take the advice of OEM if
any abnormalities noticed prior to start up of transformer.
TRANSFORMER START UP
Transformer Start up/commissioning involves the scrutiny of
mechanical aspects and electrical aspects to confirm the
integrity of before energizing the transformer .
1. It involves the physical verification of transformer, its
accessories to ensure no mechanical damages.
2. Ensuring proper signaling for alarm and trip initiation to
ensure the healthiness of protection circuits.
3. Low voltage testing of transformer to ensure the integrity of
transformer.
4. Healthy and correct connection to the bushings and tap
changers.
5. No damage to the internal and external parts during
transportation
6. Internal insulations are sound
7. Site processing if done, are adequate
8. Peripheral devices are functioning properly and control
cablings are done correctly.
Mechanical verification of transformer.
1. Earthing of transformer.
2. For any damages.
3. Installation as per Outer General Arrangement drawing.
4. Valve positioning.
5. Connection and Tightness of bushing.
6. Air releasing etc.
Electrical testing of transformer.
1. Insulation resistance of winding.
2. Voltage Ratio measurement.
3. Vector group verification.
4. Magnetic balance test.
5. Magnetizing current measurement.
6. Winding resistance measurement.
7. SFRA.
8. Tan Delta & Capacitance measurement
9. Test on transformer oil.
10. Test on Current transformer
11. Loop test.
Test on protection circuits.
12. OTI & WTI
13. PRD
14. Buchholz relay
15. MOLG
16. Surge relay
6. Leak detector etc
1. Insulation resistance of winding.
• The objective of this test is to determine whether the transformer is
in a condition to receive high voltages in to it and the condition of
the insulations involved .
• Insulation resistance is the surface and volume resistivity of the
dielectric.
• It basically depends on characteristic design and disposition of
insulation structure .
• The factors affecting the IR value are temperature ,dryness of
insulations ,cleanliness ,humidity, condition of oil etc .
• For similar designs IR values need not be same at same temperature.
• Combinations:
1. HV Winding – Earth;
2. LV Winding – Earth &
3. HV Winding – LV Winding
Test Voltage : 5 kV/2.5 kV DC Voltage
Instrument used : Insulation tester
2. Voltage ratio measurement
This is an acceptance test for a transformer .
For transformers in service this can be used for investigating
problems and as a part of routine maintenance program .
This test verifies:
1. Correctness of design
2. Correctness of connection to tap changer
3. Presence of any short circuited turn
Ratio test is carried out between a pair of winding and in all taps,
if tapings are there in any of the individual winding in the pair
considering.
Ratio test is carried out with the help of a Transformer turns ratio
meter.
The results is expressed as in %error and maximum allowable
limit is ±0.5 %
3. Vector group verification
Polarity and phase relation tests are of interest primarily
because of their bearing on parallel operation of transformers
and to the interconnected system .
Polarity test is applicable to single phase transformers and
phase displacement test is applicable to three phase
transformers .
The phase displacement test is conducted to determine the
angular displacement and relative phase rotation of HV and LV
vectors .
Group 1 Phase displacement = 0
eg : Yy0 ; Dd0 ; Dz0
Group 2 Phase displacement = 180
eg : Yy6 ; Dd6 ; Dz6
Group 3 Phase displacement = 30
eg : Dy1 ; Yd1 ; Yz1
Group 4 Phase displacement = 30
eg : Dy11 ; Yd11; Yz11
4. Magnetic balance test
The magnetic balance test is performed only on three-phase
transformers to check the core balance of the transformer.
It also indicate any interturn faults in the winding, faults in the
core and to verify the imbalance in the magnetic circuit .
The result of this test indicates the uniform distribution of the
flux in the transformer core.
5. Magnetizing current measurement.
This is a special test and it is usually conducted to check
healthiness of the core and windings at low voltage.
This can be used as reference for future site testing.
Reliability of this test depends upon how successfully d.c.
excitation in the core was removed when a d.c. voltage was
applied either during a resistance measurement or after a
short circuit failure . For a three phase transformer single phase
measurement may also be taken.
It may be noted that dangerous high voltages will be induced
in high voltage winding when a low voltage winding of fairly
large ratio is tested.
6. Sweep frequency response analysis (SFRA) test.
This test is used to detect any mechanical changes within the
main tank of a transformer (Winding movement or Winding
deformation).
The measurements provide information about the physical
position of the components within the main tank of a power
transformer (i.e. the position of the core, the windings, the
insulation, the
space, etc.)
Both measurements are “fingerprint” measurements – In
general, the measurements should not
change over time
7. Tan Delta & Capacitance measurement
Tan delta or Insulation power factor or die electric dissipation
factor gives the quality of insulation.
The main purpose of the tan delta test is to make sure of
maintaining a secure and reliable functioning of the
transformer.
Tan delta values provide insights into the insulation’s condition
of bushings and in windings; stable values across different
voltages suggest good insulation, while increasing values
indicate deterioration.
The objective of this test is to determine whether When tested
for the transformers in service it provides adequate information
about status of insulation of transformer and bushings .
This test is carried out with AC power supply
8. Winding resistance measurement.
Winding resistance is a reference test.
Measuring the resistance of the windings assures
that the connections are correct and the resistance
measurement indicates that there are no severe
mismatches or opens. Many transformers have
taps built into them. These taps allow the ratio to
be increased or decreased by fractions of a
percent.
If it is precisely measured, it can be used to locate fault in a
windings and contact problems of a transformer in service. This
test should be the last test to be performed on the transformer,
since the remanent of DC will affect the outcome of other tests.
After winding resistance measurement core shall be
demagnetized .
10. Test on current transformer.
Bushing Current Transformer
Current transformers are provided on the inside of transformer
and bushing act as its primary. These CTs are called bushing CTs
or BCTs.
Their main purpose is protection and measuring.
Measuring class CTs are mainly used for WTI heater circuit.
To ensure the BCTs are free from damage during transit, the
following tests are carried out.
- Insulation resistance
- Continuity of each circuit.
- Polarity
- Exciting current
- Ratio test
11. Test on transformer oil
Prior to energizing the transformer the following tests are done
on the transformer oil sample drawn from the main and OLTC
tank
• Breakdown voltage test on transformers oil
• Water content
• Specific resistance at 90C.
• Dielectric dissipation factor at 90C
• Interfacial tension
• Dissolved gas analysis
Test on protection circuits.
1. OTI & WTI
2. PRD
3. Buchholz relay
4. MOLG
5. Surge relay
6. Leak detector etc
TRANSFORMER OPERATION
• Transformer is a static device which used to transfer
power from one circuit to another without change in
frequency.
• Transformer basically consists of a primary winding
and secondary winding which is coupled by a core-
closed path for magnetic flux.
• The primary winding is connected to the single – phase
ac supply, an ac current starts flowing through it.
• A simple transformer consists of two electrical
conductors called the primary winding and the
secondary winding.
• Energy is coupled between the windings by the time
varying magnetic flux that passes through( links) both
primary and secondary windings.
Particulars of Transformer.
The transformer installed at Sagharah and
Dhafeer is an Oil filled, core type, two winding
transformer with 12/16/20
MVA,ONAN/ONAF1/ONAF2, 33.0 kV/13.8 kV
Transformer with vector Dyn1. Voltage variation
and Tap winding on HV with 17 taps and tap
variation of +5% to -15%. Step variation of 1.25%.