Training Report Winding of Transformers

By

Khushal H Sukhadia

Under The Guidance Of

Mr. Ashok Bajpai

Winding 2012

Index
Topic 1. Objective 2. Introduction 3. Types of Winding 3.1 Spiral 3.2 Helical 3.3 Cross Over 3.4 Criss Cross 3.5 Foil 3.6 Disc 4. Equipment and Machines 5. Materials Required 6. Procedure 7. Testing 8. Conclusion Page 3 3 3

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1. Objective
To learn and study the different types of windings of transformers from the theory as well as practical point of view

2. Introduction
If one draws a parallel between a transformer and a human body, the winding of the transformer would be the heart of the transformer and the current flowing in it could be compared to the blood of our body. For a smooth functioning of the transformer, its heart needs to be in its perfect condition. While the design of the winding is made by the design department, its execution depends on the skill of the winder. Design and execution of the winding plays a very important role in the over all functioning of the transformer. The winder must follow the design sheet meticulously, provide adequate insulation wherever required, and maintain the quality of the winding in all respects. Careful attention must be paid during each and every process of production. At the same time, during the design stage, careful consideration must be given to the ease of winding, time for production, etc

3. Types of Winding
Though the type of winding may vary and each winding may have its own unique characteristic, one fundamental rule applicable to all windings is that a winding made from left to right is different from that made from right to left. The reason is that the current direction in the two cases mentioned above is opposite. This property of the winding assumes significance when the vector group is to be decided. The various vector groups and their connection diagrams are shown in IS: 2026 Part IV. This is kept in mind duing the design stage and the windings and the end connections are made as per the vector group required at the customers end. The various types of windings are described below.

3.1

Spiral

Spiral winding is the simplest and the easiest type of winding. It can be imagined as a conductor wound as spring. In order to achieve the required number of turns, the conductors Raychem RPG Pvt. Ltd., Chakan 3

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may be wound in multiple layers. The conductor may be formed by using multiple individual conductors in the axial and radial direction to achieve the required cross sectional area. If more than one conductor is being used in the radial direction, consideration for transpositions must be taken into account. This type of winding is generally preferred for the LV coil as the cross sectional area of the conductor is very high. Since multiple conductors may be used with ease, production time is lower compared to other windings. Also, the number of turns in the LV coil is very few with no tappings. Hence, this type of winding is simple and effective.

Figure 1: Spiral Winding

Figure 2: Transposition

The inter layer voltage is very less for a LV coil. Hence the insulation required between layers and between turns is less. But on the contrary, if this type of winding is used on the HV coil where the number of turns are very high, the inter layer voltage becomes very high and higher amount of insulation is required for better electrical protection. This winding produces a helical effect and the axial length of the winding increases by one time the width of the conductor. Also, there is non-uniformity at the end of the winding. To counter this, end rings are a must to even out the end of the stack.

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Two turns of this winding are side by side and covers the entire winding without and space in between, there is an attractive force between two conductors. This force is directly proportional to the current in the conductor. Hence, from the mechanical construction point of view, adequate considerations must be given to the mechanical design of the winding. Generally, rectangular conductors are preferred as there is effective utilisation of space and it gives a uniform surface.

3.2

Helical

This type of winding is similar to spiral winding but many conductors are used in the radial directions and very few in the axial direction limited to a couple usually and there are spacers between two turns and also spacers between the conductors in the axial (if any). The spacers provide efficient cooling. Rectangular conductors can be used in this winding. Helical winding is made use of where efficient cooling is required. The inherent design of this winding provides room for a large cross section area of the conductor and also provides adequate mechanical strength. This type of winding is preferred for oil type transformers as only higher capacity jobs require higher cross sectional area, higher cooling and high mechanical stability. This winding is very difficult and time consuming. It also requires highly skilled winders.

3.3 Cross Over

The total number of turns is divided among many coils and the coils are connected in series to form one single winding. The finish terminal of one coil is connected to the start terminal of the successive coil. Rectangular and round conductors can be used in this wining. Usually, only a single conductor is made use of to achieve the required cross sectional area.

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Figure 3 : Cross Over Coils in CRT

Figure 4: Cross Over Coils of OFT

As the total number of turns are divided among various coils, the inter layer voltage is lesser compared to spiral winding and hence insulation required is much lesser comparatively. It is the most preferred winding for HV coils as the space between oils also provides the necessary cooling. Also, as tappings are usually on the HV coil, it is convenient to use cross over winding. From the production point of view, if there is any failure or error during the winding of the coil, it is easily rectifiable-especially for VPI and Oil type transformers.

3.4 Criss Cross

This is used when the cross sectional area of the conductor to be used is very high. When the number of conductors in the axial and radial direction become very large, it is inconvenient to use spiral winding. The conductors in the radial direction are equally divided in many layers and the divided bunch of conductors are wound one layer at a time. This makes the winding process easier. Also, the design of this winding is done in such a manner such that inter-layer transposition is achieved. This reduces the losses in the conductor. The layers of the coil are then brazed together to obtain the start and end terminals. The start and end terminals are on different sides of the coil.

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Figure 5: Criss Cross Winding. The inter-layer transposition is visible in the center of the coil

3.5

Foil

A foil, which covers the entire axial length of the coil, forms the conductor and only one turn per layer is possible. Foils are used where the cross section area of the conductor is very large and it is necessary to limit the eddy current losses in the conductor which increases tremendously with the thickness of the conductor, and hence by using foils, theses losses are minimized. In foil winding, only one turn per layer is formed. It is preferred for LV winding where there are only few turns. The foil is bare and external insulation is inserted along with the foil during the winding process. Often, if the axial length of the foil is big enough to cause inconvenience during winding, it is divided in multiple segments and all segments are wound simultaneously. Care must be taken to ensure there are no sharp edges in the foil. Foil winding is very expensive as the copper is usually imported. Also, the machine used in foil winding is very expensive. However, it is a less labour intensive process as the state of the art machine is equipped with motors and is quite user friendly.

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The leads of the winding are brazed to bus bars. Most often, the start and end terminals are taken on the same side of the coil.

3.6 Disc
The conductor is wound over itself to form a multi layer disc which will be connected with the subsequent disc such that the turns are in the same direction and the discs are in series. Rectangular conductors are used to form this winding. It is quite simple from the production point of view and not time intensive. In disc winding, we wind fractional number of turns on every disc to obtain consistent outer diameter of the coil. This winding has high mechanical strength and hence, it is able to withstand the excessive electro mechanical forces during a short circuit. This winding can be used for HV as well as the LV coils.

Figure 7: Disc Winding

Figure 8: Disc Winding

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Figure 9: Inter-disc bend

Figure 10: Fractional turns of discs

4. Equipment and Machines

Foil winding machine When a winding is to be made up of a foil, it is essential that a foil winding machine as handling the foil is difficult. Raychem RPG possesses a state of the art foil winding machine imported from Korea. The machine has separate loadings for the conductor, insulation, end insulation and edge strip, a laser guided brazing too and press rollers. A combination of the above mentioned featured makes it very convenient for the winder to realize this winding. There are few chances of errors if the winding is performed with care.

Figure 11: Foil Winding Machine

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Winding machine The conventional winding machine is equipped with the features required in a modern winding machine. A speed control feature along with a digital counter and a pneumatic tensioner is very handy and makes the winding process less cumbersome. The winding machine is capable of rotating in both directions. The tail stock is adjustable according to the length of the former to be loaded on it.

Figure 12: Winding Machine

Tensioner For the winding to be realized, the conductor need to be under a certain amount of tension is to be applied for better control. It holds the conductors in their positions if many of them are used in combinations of multiple axial and radial. The axially movable unit makes the winding easily realizable. It can be operated manually or pneumatically.

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Figure 13: Pneumatic Tensioner

Former A former, also known as mandril, is loaded on a winding machine between the head stalk and tail stalk and is used to form the temporary skeletal structure of the inner surface of the winding. After the winding is completed, the winding achieves its permanent shape and the former is removed and reused. The former is usually cylindrical in shape but for special cases an ovular cross section former may also be used. The entire winding is made on this former and is removed once the entire winding is completed. The axial length of all formers is non adjustable. For windings used in VPI and oil filled transformers, formers with adjustable diameters are used. The diameter of such formers is varied by loosening or tightening the adjusting screw. After the winding is completed, the diameter of the former is reduced with separates the winding from the former. This former can be made up of wood or steel. For windings of CRTs, non adjustable formers are made up of mild steel is used which can be separated from the winding only after the casting process is completed. These formers are capable of withstanding the high temperature and varying pressure of the oven and the

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autoclave. The former itself acts like the mold for the casting for the inner surface of the winding. An external shell forms the mold for the outer surface of the winding.

Figure 14: Adjustable formers used for OFT and VPI transformer windings

Figure 15: Non-adjustable formers used for CRT transformer windings

Other tools required are lead bending tool, bobbin stand for loading copper bobbins, cotton / fiberglass tape holder, outer diameter caliper, ratchet belt, measuring scale, continuity tester, mallet & wedges, brazing machine, tool set, wooden block/baton, flat file and lead bend holder

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5. Materials Required
Cylinder Fundamentally, cylinders are the skeleton structure for the windings of transformers. They also provide additional insulation. In general, cylinders are made up of two materials-namely fiber glass (FG) and press board sheet. For VPI transformers fiber glass cylinders are used. In oil filed transformers (OFT) press board sheet is suitably bent to form a cylinder over which the winding is made. In CRT cylinders are not inserted before winding. They are inserted during core coil assembly. Ducts and Spacers Ducts are strips that are placed axially to attain separation (radically) between two layers which is needed for cooling. Spacers are placed axially to separate two coils/discs/turns to achieve better cooling. Dog bone is a type of duct which is used in VPI and CRT. It derives its name from the shape of the duct as its cross section looks like dog bone. Hut shape is another type of duct as its cross section looks like hut. It is used when spacers need to be placed in the winding. Both of these ducts are made up of fiberglass. Spacers have a groove that can slide along the hut shaped duct. Ducts used in CRTs are made up of a polymer. They are inserted during the winding and are removed and reused after the casting process. Ducts used in OFTs are called runners. They are made up of press board sheets or wood. The spacers used here are made up of press board sheers. In place of dog bone ducts, rectangular ducts are used. Insulation and Adhesives Insulation is used to achieve electrical isolation between two conducting materials. Insulating materials lose their insulating property once the voltage applied to it reaches its breakdown voltage. Insulating materials are divided according to its ability to withstand heat. It is essential to use adequate insulation to ensure safe operation. Insulating material used in dry type transformers are fiberglass, polyester paper and Nomex paper. Nomex paper, belonging to class C insulation, is the most preferred but it is the most Raychem RPG Pvt. Ltd., Chakan 13

Winding 2012
expensive. Polyester (class F insulation) paper and fiberglass (class H insulation) are also gaining importance owing to its cheaper cost. The conductors are ordered with the required insulation or are covered manually with the required insulation during production. The materials used for insulation in OFTs are kraft paper (class A insulation). They absorb the transformer oil well and provide the required insulation. Press board ducts and wooden runners are used for inter layer cooling. Wooden runners are used where spacers are required. Enamel insulation is also gaining popularity. Capable of being used in dry and oil filled transformers, this insulation belongs to class H. Fiberglass mesh is extensively used in CRTs to provide the inter layer insulation. Also, they are wound over the ducts as they facilitate easy removal of the duct after casting process. Care is taken to provide extra insulation at the brazed spots as they are the prime spots for failure of the winding owing to sharp edges. Nomex paper glue tap is used to place the Nomex paper in place. Plastic tape meant for industrial use, of the required temperature class, is also used where required. Quick bond, silicone adhesive is used to stick the ducts n the cylinders. Fiberglass ribbon and cotton ribbon are used to hold the winding, ducts, and insulation together. Tappings and Terminals Taps are provided at the required turn position and the leads are taken out. These leads are further placed at appropriate positions during casting and core coil assembly. The terminal leads are taken out according to the drawing of the winding.

Figure 16: Tapping terminals being brazed

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Other important materials required are crape paper, cotton tape/self adhesive cotton tape, consumables for brazing, brushes, silicon sealant, fiberglass tape, ceramic spacers, aluminium / fiber glass end rings.

6. Procedure
i. ii. iii.
iv. v.

vi. vii. viii. ix. x.

The specification sheet is to be read carefully and doubts, if any, must be cleared with the supervisor. A suitable former is bolted on the winding machine with the help of a crane Select the suitable former and make the necessary adjustments to the former and adjust the tail stock of the winding machine to accommodate the former. Load the conductor bobbin in the bobbin stand and pass it in tensioner and arrange the conductors appropriately. If CRT, apply release agent (QZ24) & release paper (polyester). The winding is made after the leads are taken out according to the specification If and when brazing is to be done, care must be taken to not leave sharp edges and to provide extra insulation. At no time must the insulation be cut. The spacers and ducts are placed with care to maintain quality The winding is made according to the specification and tappings, if any, are taken out appropriately at the appropriate positions. After the winding is completed, the former is taken out by unbolting it and moved with the help of the crane.

7. Testing
In process routine test is carried out during the winding process. After a winding is completed, the resistances between all terminals are measured. This gives a fair idea about the number of turns in the winding and the quality of the winding. Continuity test is also performed.

8. Conclusion
All types of winding mentioned above, except helical winding, were observed and studied. The procedure for winding was also well documented. The importance of winding and its quality aspects were studied in detail. Also, importance of in processes testing was learnt. Raychem RPG Pvt. Ltd., Chakan 15