Detailed Project Report on amorphous metal distribution transformer
Detailed Project Report on amorphous metal distribution transformer
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AMORPHOUS METAL DISTRIBUTION TRANSFORMER
[CODE NO.3832]
Distribution transformers are used to distribute the electrical power in residential, commercial and industrial areas. Distribution transformers are energized for twenty four hours with wide variation in load; therefore they are designed to have low no-load losses. It is generally designed for maximum efficiency at about half full load. In order that the all-day efficiency is high, iron loss is made less by selecting a lesser value of flux density. In other words distribution transformers are generally designed for a lesser value of flux density. Two types of losses are inherent in the running of distribution transformers: no-load losses that occur in the transformer cores due to hysteresis and eddy current losses which are constant and present as soon as the transformer is energized and load losses that occur in the transformer’s electrical circuit due to resistive losses that are a function of loading conditions. The main no-load loss is core loss, which is associated with the time varying nature of the mag netizing force and results from hysteresis and eddy currents in the core materials. Core losses are dependent upon the excitation voltage and can increase sharply if the rated voltage of the transformer is exceeded. Hysteresis losses can be reduced by selecting low core losses material (such as amorphous metal), while eddy currents can be lowered by reducing lamination thickness. The problem has been overcome to some extent with the development of amorphous metal strips. This is achieved by compacting number of thin ribbons. This strip is commonly known as `Power Core'. Amorphous strips are four times harder than CRGO steel . The brittleness property of amorphous metal has also made it un-friendly to the transformer manufacturers. The manufacturers of amorphous core distribution transformers are very limited in the world because of two reasons, one is its high material cost and another is its brittleness property. Because of limitation of its brittleness property, in amorphous core transformers manufacturers are using square or rectangular cross section of the core.
Amorphous cores are usually produced as wounded, one-side cutting ones, due to mechanical properties of amorphous ribbons. This solution ensures the correct location of air gaps inside a core and simplifies electric windings assembling as well. Amorphous transformers are produced as 1-phase or 3-phase units, with 3-limbs or 5-limbs core construction. The capacity of currently produced amorphous transformers is limited up to 10 MVA.
The cross-section of amorphous cores is larger in comparison to silicon steel ones, due to lower saturation induction of amorphous ribbons. It results in the increase of transformer dimensions and weight. An essential part of the design of a transformer consists of the determination of the ferromagnetic material cross section core and the conductor’s cross-section area. These areas are determined from estimates of suitable values for the peak flux density the winding space factor, the stacking factor, and the full-load RMS current density in the windings. This current density depends on the mode the transformers will be operated, if intermittent or in a continuous form. The space factor is the ratio between the total conductor cross-section area and the core window area. The stacking factor is defined by the ratio between the ferromagnetic material crosssection area and the total core cross-section area
Usually, the thickness of a sheet of grain oriented silicon is 0.9 mm or higher. With the amorphous alloy this value is smaller than conventional silicon iron. This thinness, combined with its uneven surface, gives the amorphous material a space factor of only 80% compared to 95% achieved with silicon iron. The Designing of various types of core is discussed.
What are Amorphous Core Transformers (AMT’s)
The cores of conventional transformers consist of stacks of laminations that are made from silicon steel with an almost uniform crystalline structure (CRGO). In transformers with amorphous cores, a ribbon of steel is wound to form the core. The big benefit of amorphous transformers is that amorphous steel has lower hysteresis losses. Simply put this means that less energy is wasted as heat during magnetisation and de-magnetisation of the core
Amorphous metals are made of alloys that have no atomic order. They are made by rapid cooling of molten metal’s that prevents crystallisation and leaves a vitrified structure in the form of thin strips. Due to the lack of systematic structure, this type of metal has also been given the name “The Metallic Glasses”.
An amorphous metal transformer (AMT) is a type of energy efficient transformer found on electric grids. The magnetic core of this transformer is made with a ferromagnetic amorphous metal. The typical material (Metglas) is an alloy of iron with boron, silicon, and phosphorus in the form of thin (e.g. 25 μm) foils. These materials have high magnetic susceptibility, very low coercively and high electrical resistance. The high resistance and thin foils lead to low losses by eddy currents when subjected to alternating magnetic fields. On the downside amorphous alloys have a lower saturation induction and often a higher magnetostriction compared to conventional crystalline iron-silicon electrical steel.
In a transformer the no load loss is dominated by the core loss. With an amorphous core, this can be 70–80% lower than with traditional crystalline materials. The loss under heavy load is dominated by the resistance of the copper windings and thus called copper loss. Here the lower saturation magnetization of amorphous cores tend to result in a lower efficiency at full load. Using more copper and core material it is possible to compensate for this. So high efficiency AMTs can be more efficient at low and high load, though at a larger size. The more expensive amorphous core material, the more difficult handling and the need for more copper windings make an AMT more expensive than a traditional transformer.
Amorphous Metal
The amorphous metal used by ABB is a metallic alloy of iron, boron and silicon (Fe-B-Si) produced by solidifying alloy melts at rates rapid enough to prevent crystallization of the metal. Such rapid solidification leaves a vitrified solid with a random (amorphous) atomic structure, essentially as in the liquid phase. This differs from the atomic structure of conventional regular grain-oriented (RGO) silicon steel (a Fe-Si alloy), which has an organized crystalline structure. The largest volume usage of amorphous metal is in the cores of electrical distribution transformers. These materials offer, in concert, excellent magnetic characteristics and economy in production costs.In fact, the advent of Fe-B-Si amorphous metal alloys in the mid-1980s has been the most important advancement in materials for distribution transformers in the second half of the 20th century.
The disordered structure of amorphous steel and the ordered crystalline structure of regular grain-oriented steel.
Solidification rates of 106 K/s are necessary to produce Fe-B-Si amorphous metals. The high heat extraction rates constrain the solid in the form of a thin ribbon, about 25 μm thick. Since the material is thin, the application of amorphous metal is restricted to wound transformer cores. Amorphous metal cores have been in use for over 20 years in liquid-filled transformers, and this technology is now being applied to dry type transformers.
COST ESTIMATION
Plant Capacity 4 Nos/Day
Land & Building (2000 sq.mt.) Rs. 8.50 Cr
Plant & Machinery Rs. 80 Lac
Working Capital for 2 Months Rs. 2.40 Cr
Total Capital Investment Rs. 11.97 Cr
Rate of Return 24%
Break Even Point 53%
INTRODUCTION
WHAT ARE AMORPHOUS CORE TRANSFORMERS (AMT’S)
AMORPHOUS METAL
SIGNIFICANTLY LOWERED CORE LOSSES
OPTIMIZATION VIA ANNEALS
LOWER DESIGN INDUCTION LEVEL
LOSSES IN DISTRIBUTION TRANSFORMERS:
AMORPHOUS CORE
CARGO CORE
COMPARISON OF CRGO AND AMORPHOUS CORE DTS:
PROPERTIES OF AMORPHOUS METAL CORE
FEATURES OF AMORPHOUS TRANSFORMER
ADVANTAGES OF AMORPHOUS CORE TRANSFORMER
DISADVANTAGES OF AMORPHOUS METAL TRANSFORMERS. THESE
ARE AS FOLLOWS:
AMORPHOUS TRANSFORMER STANDARD RATING
HOW TRANSFORMERS WORK
TRANSFORMER CONSTRUCTION
TRANSFORMER CORE CONSTRUCTION
TRANSFORMER LAMINATIONS
TRANSFORMER CORE TYPES
TRANSFORMER WINDING ARRANGEMENTS
CORE-TYPE CONSTRUCTION
TRANSFORMER CORE
TRANSFORMER CORE LOSSES
HYSTERESIS LOSSES
EDDY CURRENT LOSSES
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS OF DISTRIBUTION TRANSFORMER
MANUFACTURING OF TRANSFORMER BROADLY COVERS THE
FOLLOWING PROCESSES:
(A) COIL WINDING
(B) CORE ASSEMBLY
FIG 2.1.A. SINGLE PHASE TRANSFORMET
(C) CORE-COIL ASSEMBLY
(D) TANK FORMATION
(E) PAINTING
(F) BOX-UP OR TANKING
(G) FINAL TESTING
1. INSULATION RESISTANCE TEST
TEST PURPOSE
TEST INSTRUMENTS
TEST PROCEDURE
2. DC RESISTANCE OR WINDING RESISTANCE TEST
TEST PURPOSE
TEST INSTRUMENT
METHOD NO: 1 (KELVIN BRIDGE METHOD FOR MEASUREMENT
OF WINDING RESISTANCE)
TEST PROCEDURE
KELVIN BRIDGE
METHOD NO: 2 (CURRENT VOLTAGE METHOD OF MEASUREMENT
OF WINDING RESISTANCE)
DC WINDING RESISTANCE TEST (CURRENT-VOLT METHOD)
TEST PROCEDURE
REQUIRED PRECAUTION
TEST ACCEPTANCE CRITERIA
TEST CAN DETECT
3. TURNS RATIO/VOLTAGE RATIO TEST
TEST PURPOSE
TEST INSTRUMENTS
METHOD NO 1 TURNS RATIO TESTING
TEST PROCEDURE
TRANSFORMER TURNS RATIO METER (TTR)
BRIDGE CIRCUIT
THEORETICAL TURNS RATIO = HV WINDING VOLTAGE / LV
WINDING VOLTAGE
TEST CAUTION
METHOD NO 2 VOLTAGE RATIO TESTING
TEST PROCEDURE
TEST ACCEPTANCE CRITERIA
TEST CAN DETECT
4. POLARITY/VECTOR GROUP TEST
PURPOSE OF TEST
TEST INSTRUMENTS
TEST PROCEDURE
5. SHORT CIRCUIT TEST
TEST PURPOSE
TEST INSTRUMENT
MEGGER, MULTI METER, CT, PT
TEST PROCEDURE
SHORT CIRCUIT TEST (WITHOUT USING CT, PT)
SHORT CIRCUIT TEST (WITHOUT CT)
SHORT CIRCUIT TEST (WITH CT)
ACCEPTANCE CRITERIA
TEST CAN DETECT
6. OPEN CIRCUIT / NO LOAD TEST
TEST PURPOSE
TEST INSTRUMENTS
TEST PROCEDURE
TEST CAUTION
ACCEPTANCE CRITERIA
7. CONTINUITY TEST
PURPOSE OF TEST
TEST INSTRUMENTS
TEST PROCEDURE
TEST CAN DETECT
8. MAGNETIC CURRENT TEST
TEST PURPOSE
TEST INSTRUMENT
TEST CIRCUIT DIAGRAM
MAGNETIC CURRENT TEST
TEST PROCEDURE
TEST CAUTION
9. MAGNETIC BALANCE TEST
TEST PURPOSE
TEST INSTRUMENT
TEST CIRCUIT DIAGRAM
MAGNETIC BALANCE TEST
TEST PROCEDURE
10. HIGH VOLTAGE TESTS ON HV & LV WINDING
PURPOSE
TEST INSTRUMENT
TEST CIRCUIT DIAGRAM
HV HIGH VOLTAGE TEST
LV HIGH VOLTAGE TEST
TEST PROCEDURE
11. DIELECTRICAL TEST
TEST PURPOSE
TEST INSTRUMENTS
TEST PROCEDURE
METHOD NO 1 (SEPARATE SOURCE VOLTAGE WITHSTAND TEST)
DIELECTRIC TEST (SEPERATE VOLTAGE SOURCE WITHSTAND TEST)
METHOD NO 2 (INDUCED SOURCE VOLTAGE WITHSTAND TEST)
ACCEPTANCE CRITERIA
DIELECTRIC TEST (INDUCED VOLTAGE TEST)
ACCEPTANCE CRITERIA
METHOD NO 3 LIGHTING IMPULSE TEST
12. TEMPERATURE RISE TEST OF TRANSFORMER
(H) FINISHING AND DISPATCH
MARKET POSITION
GROWING DEMAND
MARKET SIZE AND TRENDS
TRANSFORMERS INDUSTRY IN INDIA: OPPORTUNITIES & CHALLENGES
POWER AND DISTRIBUTION TRANSFORMERS INDUSTRY IN INDIA
MAJOR GROWTH DRIVERS
THE CHALLENGES
KEY TARGETS TO ACHIEVE IN TRANSFORMER BUSINESS
AS PER PATEL OF JDS GROUP THE KEY TARGETS TO ACHIEVE ARE:
TRANSFORMER INDUSTRY POISED FOR GROWTH
STUMBLING BLOCKS
AVAILABILITY OF CRGO STEEL
FAILURE RATE OF DISTRIBUTION TRANSFORMER
OUTLOOK
KEY PLAYERS
GLOBAL DISTRIBUTION TRANSFORMER MARKET - OVERVIEW
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF AMORPHOUS
DISTRIBUTION TRANSFORMER
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF AMORPHOUS RIBBON
SUPPLIERS OF DPC COPPER WINDING WIRE
SUPPLIERS OF HOT ROLLED SHEETS
SUPPLIERS OF M.S. CHANNELS AND ANGLES
SUPPLIERS OF M.S. FLAT
SUPPLIERS OF M.S. PLATE
SUPPLIERS OF M.S. PIPE
SUPPLIERS OF TRANSFORMER OIL
SUPPLIERS OF CRAFT PAPER
SUPPLIERS OF M.S BOLTS AND NUTS
SUPPLIERS OF TRANSFORMER BUSHINGS
SUPPLIERS OF PAINT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF TRANSFORMER COIL WINDING MACHINE
SUPPLIERS OF OIL FILTER MACHINE
SUPPLIERS OF VACCUME IMPREGNATION PLANT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENT
SUPPLIERS OF TRANSFORMER OIL TESTING KIT
SUPPLIERS OF BENCH GRINDER
SUPPLIERS OF DRILLING MACHINE
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF WELDING MACHINE
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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