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

(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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Detailed Project Report (DPR) includes Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.

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