Detailed Project Report on high voltage transformer
Detailed Project Report on high voltage transformer
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HIGH VOLTAGE TRANSFORMER
[CODE NO.3930]
General Overview of High Voltage Transformer
High voltage transformers are utilized for conversion of voltages from one level or phase configuration to another (from higher to lower). These transformers are known to include distinctive features such as control and instrumentation applications, electrical isolation, power distribution and others. The high voltage transformers work on the principle of magnetic induction between coils to convert current levels and/or voltage.
Various specifications need to be considered while searching for high voltage transformers. Tehse include maximum power rating, maximum secondary voltage rating, output type, maximum secondary current rating, and much more. More than one secondary voltage value may be provided by the transformer. The rated power of the transformer is the sum of VA (Volts X amps) and the out put choices normally include AC and DC.
Energy Losses of High Voltage Transformers
It is important to understand the construction and maintenance of high voltage power transformers which include information pertaining to condition monitoring techniques, degradation processes, maintenance techniques and much more. Energy losses in an ideal transformer would be none and should depict 100% efficiency. The energy of a high voltage transformer is dissipated in the core, windings and surrounding structures. Energy losses in the transformer arise from Winding Resistance, Hysteresis Losses, Eddy Currents, Magnetostriction, Mechanical Losses and Stray Losses.
Industry Overview of High Voltage Transformer
- Competitive Players:
The key players of high voltage transformers include Siemens, ABB, GE, Hitachi, Toshiba, XD Group, Mitsubishi, China Electric Equipment Group (CEEG) and few more. Various strategies and collaborations are undertaken by these players to combat prevalent competition within the market.
- Market by Types:
High voltage transformer market is further divided into Three-Phase Transformer and Single-Phase Transformer.
- Market Analysis
The market for high voltage transformers is segmented into: North America, Latin America, Russia, Europe, Japan, Middle East and Africa. The high voltage transformer market is at the peak due to increased requirements of global energy production over the past decade, which in turn has led to the increasing need for expanding T&D networks globally. To meet the growing energy demands, related infrastructure is being developed such as substations, power lines and various associated new technologies – thereby increasing the demand of high voltage transformers.
Reliability and grid stability have driven new investments and overall spending in the distribution markets. The high voltage power transformer market is largely controlled by four major market players – Siemens AG (Germany), Toshiba (Japan), General Electric (U.S) and ABB (Switzerland). These control nearly half of the overall market. These organizations have the advantage of having manufacturing operations which vcater to network expansion hotspots such as Asia-Pacific and Middle-East.
Market Segmentation
The market of High Voltage Transformers is segmented into Energy and Power Utilities, Power Generation, Power Distribution and Power Transmission.
Key Market Drivers
The key drivers of this market include (a) Rose in growth of the micro grid and power generation and transmission technologies (b) growth in industrialization and centralization
Challenges
The market of high voltage transformer depicts cost and reliability challenges, market landscape, technological launches, acquisitions, and much more.
COST ESTIMATION
Plant Capacity : O.1666 Nos/Day
Land & Building (10000 sq.mt.) : Rs. 5.76 Cr
Plant & Machinery : Rs. 2.29 Cr
Working Capital for 2 Month : Rs. 16.04 Cr
Total Capital Investment : Rs. 24.37 Cr
Rate of Return : 82%
Break Even Point : 21%
INTRODUCTION
PRINCIPLE OF TRANSFORMER
TYPES OF TRANSFORMER
POWER TRANSFORMER
DISTRIBUTION TRANSFORMER
CONSTRUCTION OF POWER TRANSFORMER
PARTS OF A TRANSFORMER
STEEL TANK:
CORE OF TRANSFORMER:
WINDINGS:
CONSERVATOR TANK:
BREATHER:
THERMOMETER:
PRESSURE RELIEF VENT:
VALVES:
BUCHHOLZ RELAY
BUSHINGS:
TAP CHANGING SWITCH
OFF LOAD TAP CHANGER
OIL GAUGE:
RADIATOR:
COOLING FANS:
OIL PUMPS:
USES AND APPLICATION
USES
APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
(A) COIL WINDING
HIGH VOLTAGE COIL
LOW VOLTAGE COIL
(B) CORE ASSEMBLY
(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
TRANSFORMER TURNS RATIO METER (TTR)
BRIDGE CIRCUIT
TEST CAUTION
METHOD NO 2 VOLTAGE RATIO TESTING
TEST PROCEDURE
TEST ACCEPTANCE CRITERIA
TEST CAN DETECT
4. POLARITY / VECTOR GROUP TEST 57
PURPOSE OF TEST
TEST INSTRUMENTS
TEST PROCEDURE
5. SHORT CIRCUIT TEST
TEST PURPOSE
TEST INSTRUMENT
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 (SEPARATE 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
MARKET STUDY ON INDIA'S POWER & DISTRIBUTION TRANSFORMER
INDUSTRY TRENDS
EXTENSIVE APPLICABILITY IN HIGH VOLTAGE APPLICATIONS AND HARSH OPERATING CONDITIONS STRENGTHEN THE DEMAND FOR SHELL POWER TRANSFORMERS 79
INCREASING FOCUS TOWARD MEETING THE BURGEONING POWER
DEMAND WILL BOOST THE ASIA PACIFIC INDUSTRY SIZE
POWER AND DISTRIBUTION TRANSFORMERS INDUSTRY IN INDIA
MAJOR GROWTH DRIVERS
THE CHALLENGES
KEY TARGETS TO ACHIEVE IN TRANSFORMER BUSINESS
KEY TARGETS
PLANT LAYOUT
SUPPLIERS OF POWER TRANSFORMER
SUPPLIERS OF RAW MATERIALS
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 CARGO LAMINATION
SUPPLIERS OF DPC COPPER WINDING WIRE
SUPPLIERS OF TRANSFORMER OIL
SUPPLIERS OF KRAFT PAPER
SUPPLIERS OF M.S BOLTS AND NUTS
SUPPLIERS OF TRANSFORMER BUSHINGS
SUPPLIERS OF PAINT
SUPPLIERS OF PLANT AND MACHINERIES
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 FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATEFARM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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