Overview of the Factory
The transformer repairing factor is equipped with state-of-the-art technology to repair transformers of various types, including power transformers. distribution transformers and special transformers. The factory spans over approximately
acres and includes several production and repairing units and assembly lines. testing facilities,
and quality assurance labs, testing units, final testing units, etc.
- Power and distribution transformer up to 600 KVA, 33 KVA
- For the repairing of weir and distribution transformers up to 5000 KVA, 66 KV
- For installation and commissioning of power and distribution transformers at the customer site.
- Annual contract for servicing customers transformers at their site.
Transformers are designed for repair and tested as per the information given by WBSEDCL. The transformers are finally tested by a highly technical and experienced engineer.
Transformer Repairing Process :
Transformers are very important machinery in power electrical networks that are used to step up or step down voltages in order to facilitate efficient transmission and distribution of electricity. Transformers are capable, with time, of developing faults or wearing out and, therefore, must be repaired to continue to serve effectively. This report identifies the most essential steps involved during transformer repair.
1. Identification of Faults
Symptoms of Failure: Common signs of transformer issues include
overheating, unusual noises, oil leaks, reduced efficiency, or failure to operate.
Diagnostic Testing: Tests such as insulation resistance
Measurement, turns ratio testing, dissolved gas analysis (DGA), and power factor testing are conducted to identify the root cause of the problem.
2. De-energization and Isolation
- The transformer is de-energized from the power supply and insulated for safety while it is being repaired.
- Proper lockout/tagout procedures are followed to prevent accidental re-energization.
3. Drainage and Inspection:
oil Draining: Transformer oil is drained and retained for filtration
or substitute.
Internal Inspection: The transformer is opened and internal
Such things as windings, cores, bushings, and tap changers are checked for wear or damage.
4. Replacement or Repair of Parts
a) Core Repair: Damage to the core is examined, and laminations are remanufactured or replaced if needed.
Core refers to the majority portion of the transformer, and efficiency will be a function of its quality. The plant uses high-grade silicon steel plates and stacks them together to form the core. It will be processed to minimize the loss as well as enhance the magnetic properties.
b) Winding Repair: The defective windings are repaired or replaced.
This can include the rewinding of the coils of the transformer. Winding is done through copper or aluminum in a controlled environment. The winding is done with precision so that the electrical characteristics of the transformer meet the standard. Automatic machines are used by the factory for accuracy and convenience.
c) Winding & Core Insulation: Transformer core and winding
Insulation safeguards the transformer’s internal components against damage. It also allows the transformer to operate safely and efficiently. It consists of materials such as paper, oil, and resin.
d) Bushing and Insulation: Faulty bushings and insulation materials are replaced to restore dielectric strength.
5. Reassembly and Oil Filling
The replaced core and windings are carefully reassembled in the transformer tank.
Installed are additional components such as tap changers, bushings, and insulation. The transformer is welded and sealed, hence making sure the transformer is airtight so as to avoid oil leakage from the tank.
Assembling parts on transformer tank
After assembly, transformers are filled with insulating oil (mineral oil or other types). The oil is vacuumed into the tank to eliminate air pockets, which helps in cooling and insulating
the electrical components
Oil filing into the tank
6. Testing and Quality Control
There is a series of tests that a transformer goes through, some of which include
- Dielectric Testing Checking the insulation resistance.
- Performance under load conditions: load test.
Temperature Rise Test: To check whether the transformer gets its power withstanding temperature fluctuations or not.
- Dissolved Gas Analysis (DGA): This is oil sample analysis to check for any abnormal gas levels.
According to the WBSEDCL testing sheet, all tests are processed
7. Key Technologies and Equipment
Winding Machines: The workshop uses both semi-automatic and fully automatic winding machines, which improve efficiency and ensure the uniformity of windings.
Vacuum Oil Treatment : A vacuum treatment system is used to
Eliminate any air or moisture. Once the oil is filled, it prevents potential problems such as insulation breakdown.
Automated Testing System: It is a system that performs different tests and records results automatically to maintain proper quality control.
8. Quality Control and Safety Measures
Raw materials are inspected. All incoming material, including
They have quality and specification checking of the copper wire, steel sheets and insulation materials
In-process Inspections: Throughout out, routine inspections are done
It accepts the winding, assembly, and oil-filling processes to guarantee the safety and technical standards.
Final Evaluation and Testing: After assembly, the transformer
Reliability and operational performance are subjected to thorough evaluation, within dedicated testing facilities, to verify the reliability of the system
9. Observations and Recommendations
- If they are neglected, there will be major failures, but if they are maintained and monitored regularly, they can be prevented.
- Repair them with high-quality materials and follow manufacturer guidelines.
- Teach personnel how to safely and effectively repair transformers.
Conclusion:
The visit to the transformer-repairing factory gave me an insight into the intricacies of transformer repair. This is a very complex and crucial process that requires expert knowledge and specialized equipment. The accurate diagnosis, the effective repair, and the thorough testing of transformers are crucial to keep transformer reliability, to reduce transformer downtime, and to maintain the efficiency of the power system.
The workshop’s ability to continue to innovate, advance automation, and pursue sustainable practices has the potential to further optimize its operations and further expand its range of products.