BHARAT HEAVY

ELECTRICALS LIMITED
JHANSI

PROJECT REPORT ON
WORKING OF TAP CHANGER (ON LOAD / OFF
CIRCUIT)

SUBMITTED TO: UNDER GUIDENCE OF:

MR. DHRUV BHARGAVA ER. PRABHAT KATIYAR
DGM HRD DEPTT. BAY-9
BHEL JHANSI BHEL JHANSI

SUBMITTED BY:
ANKIT KUMAR
ELECTRICAL ENGINEERING
BIET JHANSI
 ACKNOWLEDGEMENT
My first experience of project has been successful. First of all, I am thankful to my project
guide, ER. PRABHAT KATIYAR under whose guideline I was able to complete the project.
I am whole heartedly thankful to him for giving me his valuable time & attention. I wish to
place heartily thanks to all those who encouraged me throughout the study and provided me
the opportunity to learn as a trainee at BHEL Jhansi.

The disciplined environment in BHEL Jhansi has also played a vital role in timely completio n
of this training.

ANKIT KUMAR

B.TECH EE 3rd YEAR

BIET JHANSI
 CONTENT
 Vision, mission and values of BHEL 1
 Overview of BHEL 2
 Various units of BHEL 4
 Activity profile of BHEL 5
 BHEL Jhansi (unit) 7
 Various department of BHEL Jhansi 10
 Health, safety & environment management 20
 An Introduction To On Load Tap Changer 22
 On-Load Tap-Changers For Power Transformers 24
 Design Concept Of On Load Tap Changer 27
 Description Of Equipments 29
 Installation Of OLTC 35
 Test Performed On OLTC 44
 Transportation And Operation Of OLTC 46
 Supervision And Inspection 47
 Conclusion 49
 References 50
INTRODUCTION TO
BHEL
 (1) VISION, MISSION AND VALUES OF BHEL

VISION
A global engineering enterprise providing solutions for a better tomorrow.

MISSION
Providing sustainable business solutions in the fields of Energy, Industry & Infrastructure.

VALUES
 GOVERNANCE: We are stewards of our shareholders investments and we take that
responsibility very seriously. We are accountable and responsible for deliver ing
superior results that make a difference in the lives of the people we touch.

 RESPECT: We value the unique contribution of each individual. We believe in

respect for human dignity and we respect the need to preserve the environment around
us.

 EXCELLENCE: We are committed to deliver and demonstrate excellence in

whatever we do.

 LOYALTY: We are loyal to our customers, to our company and to each other.

 ENTEGRITY: We work with highest ethical standards and demonstrate a behaviour

that is honest, decent and fair. We are dedicated to the highest levels of personal and
institutional integrity.

 COMMITMENT: We set high performance standards for ourselves as individ ua ls

and our teams. We honour our commitments in a timely manner.

 INNOVATION: We constantly support development of newer technologies, products,

improved processes, better services and management practices.

 TEAM WORK: We work together as a team to provide best solutions & services to
our customers. Through quality relationships with all stakeholders we deliver value to
our customers.
 (2) AN OVERVIEW OF BHEL
BHEL is the largest engineering and manufacturing enterprise in India in the
energy/infrastructure sector today. BHEL was established more than 40 years ago when its first
plant was set up in Bhopal ushering in the indigenous Heavy Electrical Equipment industry in
India, a dream that has been more than realized with a well-recognized track record of
performance.
BHEL caters to core sectors of the Indian Economy viz., Power Generation & transmiss io n,
Industry, Transportation, Telecommunication, Renewable Energy, Defence, etc. The wide
network of BHEL’s 17 manufacturing divisions, four Power Sector regional centres, over 100
project sites, eight service centres and 18 regional offices, enables the company to promptly
serve its customers and provide them with suitable products, systems and services-efficie ntly
and at competitive prices. BHEL has already attained ISO 9000 certification for quality
management, ISO 27000 for Information Technology and ISO 14001 certification for
environment management.

POWER GENERATION
Power generation sector comprises thermal, gas, hydro, and nuclear power plant business .

TELECOMMUNICATION

BHEL also caters to Telecommunication Sector by way of small, medium and large switching
systems.

TRANSMISSION AND DISTRIBUTION (T&D)

BHEL offers wide-ranging products and systems for T&D applications. Products manufactured
include: power transformers, instrument transformers, dry type transformers, series &shunt
reactors, capacitor banks, vacuum &SF6 circuit breakers, gas-insulated switchgears and
insulators.

INDUSTRIES
BHEL is a major contributor of equipment and systems to industries, cement, sugar, fertilizer,
refineries, petrochemicals, paper, oil and gas, metallurgical and other process industries. The
range of systems & equipment supplied includes: captive power plants, co-generation plants,
DG power plants, industrial steam turbines, industrial boilers and auxiliaries, waste heat
recovery boilers, gas turbines, heat exchangers and pressure vessels, centrifugal compressors,
electrical machines, pumps, valves, seamless steel tubes, electrostatic precipitators, fabric
filters, reactors, fluidized bed combustion boilers, chemical recovery boilers and process
controls.

TRANSPORTATION
BHEL is involved in the development, design, engineering, marketing, production, installatio n,
and maintenance and after-sales service of rolling stock and traction propulsions systems.
BHEL manufactures electric locomotives up to 5000 HP, diesel electric locomotives from 350
HP to 3100 HP, both for mainline and shunting duty applications. It also produces rolling stock
for special applications viz. overhead equipment cars, special well wagons, and Rail-cum road
vehicle.
RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable
sources of energy include: wind electric generators, solar photovoltaic systems, solar heating
systems, solar lanterns and battery-powered road vehicles.

OIL AND GAS

BHEL’s products range includes Deep Drilling Oil Rigs, Mobile Rigs, Work Over Rigs, Well
Heads and X-Mas Trees, Choke and Kill Manifolds, Full Bore Gate Valves, Mudline
Suspension System, Casing Support system Sub-Sea Well Heads, Block valves, Seamless
pipes, Motors, Compressor, Heat Exchangers etc.

INTERNATIONAL OPERATIONS
BHEL is one of the largest exporters of engineering products & services from India, ranking
among the major power plant equipment suppliers in the world.
 (3) VARIOUS BHEL UNITS

FIRST GENERATION UNITS

Bhopal : Heavy Electrical Plant.
Haridwar : Heavy Electrical Equipment Plant.
Hyderabad: Heavy Electrical Power Equipment Plant.

SECOND GENERATION UNITS

Tiruchy : High Pressure Boiler Plant.
Jhansi : Transformer and Locomotive Plant.
Haridwar : Central Foundry and Forge Plant.
Tiruchy : Seamless Steel Tube Plant.

UNITS THROUGH ACQUISTION & MERGER

Bangalore : Electronics Division Electro Porcelain Division.

NEW MANUFACTURING UNITS

Ranipet : Boiler Auxiliaries Plant.
Jagdishpur: Insulator Plant.
Govindwal : Industrial Valve Plant.
Rudrapur : Component and Fabrication Plant.
Bangalore : Energy Systems Division
BHEL is growing concern to meet the changing needs of the nation has taken it beyond power
into the total gamut of energy, industry and transportation BHEL is able to offer a service in
each of this fields. Its manufacturing capability is supported by a corporate R&D division at
Hyderabad works closely with the research and development cells at various units and Welding
Research Institute at Tiruchinapalli.
 (4) ACTIVITY PROFILE OF BHEL
POWER SECTOR PROJECTS

 Thermal sets and Auxiliaries.

 Steam generators and Auxiliaries.
 Industrial fans.
 Electrostatic precipitators.
 Air pre heaters.
 Nuclear power equipments.
 Hydro sets and Auxiliaries.
 Motors.
 Transformers.
 Rectifiers.
 Pumps.
 Heat Exchangers.
 Capacitors.
 Porcelain/Ceramics insulators.
 Seamless steel tubes.
 Casting and forging.

SYSTEMS/SERVICES

 Turnkey power station.

 Data acquisition Systems.
 Power systems.
 HVDC Commissioning systems.
 Modernization and Rehabilitation.

TRASPORTATION SECTOR

 Diesel Electric generators.

 AC/DC locomotives.
 DC locomotives and loco shunters.
 Traction system for railways.
 Electric trolley buses.
INDUSTRY SECTOR

 Boilers.
 Valves.
 T.G. sets.
 Power devices.
 Solar Cells.
 Photo Voltaic cells.
 Gas Turbines.
 Compressors.
 Drive Turbines.
 Oil rigs.
 Blow out preventers.
 Wind mills.
 Control systems for electric devices.
 (5) BHARAT HEAVY ELECTRICALS LIMITED JHANSI (UNIT)

A BRIEF INTRODUCTION
By the end of 5th five-year plan, it was envisaged by the planning commission that the demand
for power transformer would rise in the coming years. Anticipating the country’s requireme nt
BHEL decided to set up a new plant, which would manufacture power and other types of
transformers in addition to the capacity available in BHEL Bhopal. The Bhopal plant was
engaged in manufacturing transformers of large ratings and Jhansi unit would concentrate on
power transformer upto 50 MVA, 132 KV class and other transformers like Instrume nt
Transformer s, Traction transformers for railway etc.

This unit of Jhansi was established around 14 km from the city on the N.H. No 26 on Jhansi
Lalitpur road. It is called second-generation plant of BHEL set up in 1974 at an estimated cost
of Rs 16.22 crores inclusive of Rs 2.1 crores for township. Its foundation was laid by late Mrs.
Indira Gandhi the prime minister on 9 th Jan. 1974. The commercial production of the unit began
in 1976-77 with an output of Rs 53 lacs since then there has been no looking back for BHEL
Jhansi.

The plant of BHEL is equipped with most modern manufacturing processing and testing
facilities for the manufacture of power, special transformer and instrument transformer, Diesel
shunting locomotives and AC/DC locomotives. The layout of the plant is well streamlined to
enable smooth material flow from the raw material stages to the finished goods. All the feeder
bays have been laid perpendicular to the main assembly bay and in each feeder bay raw material
smoothly gets converted to sub assemblies, which after inspection are sent to main assembly
bay.

The raw material that are produced for manufacture are used only after thorough material
testing in the testing lab and with strict quality checks at various stages of productions. This
unit of BHEL is basically engaged in the production and manufacturing of various types of
transformers and capacities with the growing competition in the transformer section, in 1985-
86 it under took the re-powering of DESL, but it took the complete year for the manufactur ing
to begin. In 1987-88, BHEL has progressed a step further in under taking the production of AC
locomotives, and subsequently it manufacturing AC/DC locomotives also.
PRODUCT PROFILE OF BHEL JHANSI UNIT
1. Power transformer up to 400 KV class 250 MVA.

2. Special transformer up to 180 KV.

3. ESP transformer 95 KV, 1400 mA.

4. Freight Loco transformer 3900 to 5400 KVA & 7475 .

KVA for 3 phase.

5. ACEMU transformer up to 1000 KVA (1-phase).

1385 KVA (3 phase). .

6. Dry type transformer up to 6300 KVA 33 KV class

7. Instrument transformer VT & CT up to 220 KV class.

8. Diesel electric locomotives up to 2600 HP.

9. AC/DC locomotives 5000 HP.

10. Over Head Equipment cum Test Car

11. Well wagon 200 tone.

12.Rail cum road vehicle

13. Dynamic track stabilizer

BHEL PERFORMANCE (CORPORATE LEVEL)

PARAMETER 2011 - 12 2012 - 13

Turnover (Rs. /Cr.) 49510 50015

Order Inflow (Rs. /Cr.) 22096 31528

Net Profit (Rs. /Cr.) 7040 6485

Net Worth (Rs. /Cr.) 25373 30315

Megawatts Commissioned 9270 10340

R & D Investment (Rs. /Cr.) 1199 1248

Patents/Copyrights Filed (Nos.) 351 385

 MAJOR UNITS TURNOVER (In Rs. /Crores)

DIVISION 2011 – 12 2012 – 13

(Actual) (Provisional

JHANSI 1300 1365

CFFP HARDWAR 506 523

HEEP HARDWAR 5415 6375

BAP RANIPET 4210 3703

HPBP TRICHY/SSTP 14571 14970

EDN BANGALORE 2301 1650

BHOPAL 4790 4703

HEEP HYDERABAD 7072 6408

BHEL NET 49301 50015

 (6) VARIOUS DEPARTMENTS/FUNCTIONS AT BHEL JHANSI
TRANSFORMER COMMERCIAL (TRC)
The objective of the department is interaction with the customers. It brings out tenders and
notices and also responds to them. It is this department that bags contracts of building
transformers. After delivery regarding faults, this department does failures and maintena nce.
All such snags are reported to them and they forward the information to the concerning
department.
One of the major tasks of this department is to earn decent profits over all negotiatio ns.
Transformer industry has become very competitive. The company offering the lowest price
gets the contract but this process may continue does the work on very low profits. To avoid
such a situation, a body by the name of India Electrical and Electronics Manufactur ing
Association (IEEMA) was set up. This association helps to maintain a healthy competitive
atmosphere in the manufacturing of electrical appliances.

TRANSFORMER ENGINEERING (TRE)

The transformer manufactured in BHEL Jhansi range from 10 MVA to 250 MVA and up to
400 KV. The various transformers manufactured in this unit are:-

POWER TRANSFORMER
a) Generator transformer
b) System transformer.
c) Auto transformer.

SPECIAL TRANSFORMER
a) Freight loco transformer.
b) ESP transformer.
c) Instrument transformer.
d) Dry type transformer.

BAY-00 & 0:
It is a sub part of Fabrication. It is the preparation shop while the other two bays form the
assembly shop. This section has the following machines:

 Planner machine – To reduce thickness

 Shearing machine
 CNC / ANC Flame Cutting machine – To cut Complicated shaft items using Oxy-
Acetylene flame
 Bending machine
 Rolling machine
 Flattening machine
  Drilling machine
 Nibbling machine
 Pantograph flame cutting machine
BAY-1
It is also a sub part of Fabrication. It is an assembly shop where different parts of tank come
from bay 0.Here welding processes are used for assembly, after which a rough surface is
obtained Grinder operating at 1200 rpm is used to eliminate the roughness.

BAY-2
It is also a sub part of Fabrication It is an assembly shop dealing with making different objects
mentioned below.
1-Tank assembly 5-cross feed assembly

2-Tank cover assembly 6-core clamp assembly

3-End Frame assembly 7-pin and pad assembly

4-foot assembly

Before assembly, short blasting (firing of small materials i.e., acid pickling) is done on
different parts of jobs to clean the surface before painting.

NON DESTRUCTIVE TEST

1. Ultrasonic test to detect the welding fault on the CRO at the fault place high amplitude
waves are obtained.

2. Die Penetration test Red solution is put at the welding and then cleaned. After some time
white solution is mixed. Appearance of a red spot indicates a fault at the welding.

3. Magnetic crack detection Magnetic field is created and then iron powder is put at the
welding. Sticking of the iron powder in the welding indicated a fault.

4. X-Ray Test: It is same as human testing and the fault is seen in X-ray film.

BAY-3
Here are basically three sections in the bay:

 Machine section
 Copper section
 Tooling section

BAY 4
It is the winding section.

There are four types of coil fixed in a transformer, they are

 1. Low voltage coil (LV)
2. High voltage coil (HV)
3. Tertiary coil
4. Tap coil
The type of winding depends upon job requirement. Also, the width and thickness of the
conductors are designed particulars and are decided by design department. Conductors used
for winding is in the form of very long strips wound on a spool, the conductor is covered by
cellulose paper for insulation.

For winding first the mould of diameter equal to inner dia meter of required coil is made .The
specification of coil are given in drawing. The diameter of mould is adjustable as its body is
made up of wooden sections that interlock with each other. This interlocking can be increased
or decreased to adjust the inner diameter of coil.

The moulds are of following types

1. Belly types
2. Link types
3. Cone type

BAY-5
It is core and punch section. The lamination used in power, dry, ESP transformer etc for
making core is cut in this section.

CRGO (cold rolled grain oriented) silicon steel is used for lamination, which is imported in
India from Japan, U.K. Germany. It is available in 0.27 and 0.28 mm thick sheets, 1mt wide
and measured in Kg. .The sheet s are coated with very thin layer of insulating material called
“carlites”.

For the purpose of cutting and punching the core three machines are installed in shop

BAY-6
Single-phase traction transformer for AC locomotives is assembled in this section. This
Freight locomotive transformers are used where there is frequent change in speed. In this bay
core winding and all the assembly and testing of traction transformer is done.

Three-phase transformers for ACEMU are also manufactured in this section. The supply lines
for this transformer are of 25 KV and power of the transformer is 6500 KVA. The tap changer
of rectifier transformer is also assembled in this bay. Rectified transformer is used in big
furnace like the thermal power stations / plants (TPP).

BAY-7
1. This is the insulation shop. Various types of insulations are
2. AWWW - All Wood Water Washed press paper.
3. The paper is 0.2-0.5mm thick cellulose paper and is wound on the
conductors for insulation.
 4. PRE COMPRESSED BOARD: This is widely used for general insulation &
separation of conductors in the forms of blocks.
5. PRESS BOARD: This is used for separation of coils e.g. L.V. from H.V. It is up to
38 mm thick.
6. UDEL(Un Demnified Electrical Laminated) wood or Permawood
7. This is special type of plywood made for insulation purposes.
8. FIBRE GLASS: This is a resin material and is used in fire pron areas.
9. BAKELLITE
10. GASKET- It is used for protection against leakage.
11. SILICON RUBBER SHEET- It is used for dry type transformer.

BAY 8
It is the instrument transformer and ESP transformer manufacturing section.

INSTRUMENT TRANSFORMER

These are used for measurement. Actual measurement is done by measuring instruments but
these transformers serve the purpose of stepping down the voltage to protect the measuring
instrument. They are used in AC system for measurement of current voltage and energy and
can also be used for measuring power factor, frequency and for indication of synchronis m.
They find application in protection of power system and for the operation of over voltage,
over current, earth fault and various other types of relays.

ESP TRANSFORMER

The Electrostatic Precipitator transformer is used for environmental application. It is used to

filter in a suspended charge particle in the waste gases of an industry. They are of particular
use in thermal power stations and cement industry.

The ESP is a single-phase transformer. It has a primary and secondary. The core is lamina ted
and is made up of CRGOS. It is a step up transformer. An AC reactor is connected in series
with primary coil. The output of the transformer must be DC this is obtained by rectifying AC
using a bridge rectifier (bridge rectifier is a combination of several hundred diodes). A radio
frequency choke (RF choke) is connected in series with the DC output for the protection of the
secondary circuit and filter circuit. The output is chosen negative because the particles are
positively charged. The DC output from the secondary is given to a set of plates arrange one
after the others. Impurity particles being positively charged stick to these plates, which can be
jerked off. For this a network of plates has to be setup all across the plant. This is very costly
process in comparison with the transformer cost. A relive vent is also provided to prevent the
transformer from bursting it higher pressure develops, inside it. It is the weakest point in the
transformer body. An oil temperature indicator and the secondary supply spark detector are
also provided.

One side of the transformer output is taken and other side has a ‘marshalling box’ which is the
control box of the transformer.
BAY-9

In this bay power transformer are assembled. After taking different input from different bays
0-9 assembly is done Power transformer is used to step and step down voltages at generating
and sub-stations. There are various ratings –11KV, 22KV, manufactured, they are

1. Generating transformer
2. System
3. Autotransformer.

A transformer in a process of assemblage is called a job. The design of the transformer is done
by the design deptt. & is unique of each job; depends on the requirement of customer. The
design department provides drawing to the assembly shop, which assembles it accordingly.

The steps involved in assembly are:

1. Core building
2. Core Lifting.
3. Unlacing.
4. Unlacing and end-frame mounting.
5. High voltage terminal gear and low volt terminal gear mounting
6. Vapour phasing and oil soaking
7. Final servicing and tanking.
8. Case fitting.

STORE

There are three sections in store:

1. Control Receiving Section

2. Custody Section
3. Scrap Disposal Section

LOCOMOTIVE PRODUCTION (LMP)

There are following products are manufactured at Loco shops

 Alternating Current Locomotive (ac Loco)

 WAG-5H
 AC./D.C. Loco
 WCAM-2P
 WCAM-3
W-broad gauge A-running in AC mode
C-running in DC mode G-hauling goods train
 P-hauling passenger train M-hauling passenger
& goods train
 Diesel Electric Locomotive Shunting (DESL)
 350 HP
 700 HP
 Single Power Pack (SPP): One 700 HP m/c is made as a single
Unit. It is a meter gauge locomotive

 Twin Power Pack (TPP): 2 350HP m/cs are combined in 1 engine

& can be operated individually or in combination depending on

Load.

 450 HP
 1400 HP
 1150 HP
 1350 HP
 2600 HP
1150 HP and 1350 HP DESL s are non-standard locomotives and are modified
versions of 1400 HP DESL based on requirement of customer.

Under mention are the new non-conventional products designed and developed for
Indian Railways based on their requirement.
 OHE (Overhead electric) recording and testing cars
 UTV(Utility vehicle )
 RRV(Rail cum road vehicle)
 DETV( Diesel electric tower car)
 BPRV(Battery power road vehicle)
 BCM(Blast cleaning machine)
 200 T Well wagon for BHEL Haridwar
 Metro Rake-Kolkata Metro Railways

LOCOMOTIVE MANUFACTURING (LMM)

This section deals with manufacturing of locomotives. The main parts of the locomotive are

Under frame: The frame on which a locomotive is built

Super structure: The body of locomotive is called superstructure or Shell and is made of
sheet of Mild steel

DC motor

Alternator
Compressor

Flower

Static Rectifier-MSR

Static Converter-SC

Exchanger

Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially contains

1-wheel axle arrangement

2-Suspension

3-Brake rigging

Traction transformer: It is fixed on under frame and gets supply from an overhead line by
equipment called pantograph. The type of pantograph depends on supply. This transfor mer
steps down voltage and is fitted with a tap changer. Different taps are taken from it for
operating different equipment. One tap is taken and is rectified into DC using MSR and is
fed to the DC motor.

Railways has two types of power supplies – 25 KV, 1 Phase, 50 Hz AC

1500 V DC

An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.

WORK ENGINEERING & SERVICES (WE&S)

This department looks after the commissioning and maintenance of all the machinery used
in the factory. It also has 3 two-stage air compressors for supplying compressed air to the
various bays.

The department has 03 different divisions:

 Electrical Engg.
 Electronics Engg.
 Mechanical Engg.

ELECTRICAL ENGINEERING:

This division looks after all the electrical machinery and power distribution of the factory.
Snags detected in the system are immediately reported to this dept by the concerning
dept.WE&S takes prompt action to rectify it.

The factory has a feeder of 11KV .The total load sanctioned for the factory is 2500MVA but
the maximum demand reaches the range of 1700-2000 MVA.
Here are various sub-stations (SS) inside the factory, for distribution of power to differe nt
sections.

SS -1 Supplies Bay-6 to Bay –9

SS -3 Supplies Bay 1to Bay-4

SS -4 Supplies Boiler and loco plant

SS -5 Supplies Bay -5

SS -6 Supplies Administrative building

TECHNOLOGY
This department analyses the changes taking place in the world and suggest changes
accordingly. This is very important because the products must not get obsolete in the market
otherwise they will be rejected by the customer.

FUNCTIONS: Technology functions can be classified as:

 Processing Sequence - The sequence of process of manufacturing is decided for

timely and economic completion of the job.
 Operation time estimate - It includes incentive scheme management
 Allowed operation time - It includes incentive amount
 Facilities identification - It includes looking for new equipment or plant or tools to
increase productivity
 Special process certification - Special processes are the ones requiring expertise for
example identifying errors, cracks, air bubbles in welding
 Special tools requirement - Special tools are allotted, if possible, when required
else the design has to be reconsider.
 Productivity projects compilation - It includes the initial analysis of the problem
and their appropriate solution to enhance productivity.
The principle of working is that
“IF YOU DO NOT MAKE THE CHANGES IN YOUR COMPANY, THE
CUSTOMER WILL CHANGE YOU”.

CENTRAL QUALITY SERVICE

First we get acquainted with a few terms concerning this department.

QUALITY
It is the extent to which products and services satisfy the customer needs.

QUALITY ASSURANCE
All those plants and systematic action necessary to provide adequate confidence that a product
or service will satisfy the given requirement is called quality assurance.
QUALITY CONTROL
The operational technique and activities that are used to fulfill requirement for quality are
quality control.

QUALITY INSPECTION
Activities such as measuring, testing, gauging one or more characteristics of a product or
service and comparing these with specified requirement to determine conformity are termed
quality inspection.

BHEL JHANSI PERFORMANCE

FINANCIAL (In Rs. /Crore)

PRODUCT 2011 – 12 2012 – 13 Growth %

(Actual) (Provisional)

Power Transformer 564 457 –19

Non Power Transformer 304 376 24

Loco 430 532 24

Total 1300 1365 5

PHYSICAL

PRODUCT Unit 2011 – 12 2012 – 13

(Actual) (Provisional

POWER TRFR NOS 161 135

MVA 9585 10101

ESP TRFR NOS 1280 1745

FRT LOCO TRFR- 1 PH NOS 90 108

FRT LOCO TRFR- 3PH NOS 30 44

ACEMU TRFR NOS 161 240

DRY TYPE TRFR NOS 125 105

INSTRUMENT TRFR NOS 335 404

DESL NOS 15 10

AC LOCOMOTIVE NOS 53 62

WAGON/WHEEL AXLE SET NOS 2 12

 (7) HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT
BHEL, as an integral part of business performance and in its endeavor to becoming a world
class organization and sharing the growth global concern on issues related to
Environment, Occupational Health and Safety, is committed to protecting Environment in and
around its own establishment, and providing safe and healthy working environment to all its
employees. For fulfilling these obligations, Corporate Policies have been formulated as:

ENVIRONMENTAL POLICY
 Compliance with applicable Environmental Legislation/Regulation;
 Continual Improvement in Environment Management Systems to protect our natural
environment and control pollution;
 Promotion of activities for conservation of resources by Environmental Management.
 Enhancement of Environmental awareness amongst employees, customers and
suppliers.

OCCUPATIONAL HEALTH AND SAFETY POLICY

 Compliance with applicable Legislation and Regulations.
 Setting objectives and targets to eliminate/control/minimize risks due to Occupational
and Safety Hazards.
 Appropriate structured training of employees on Occupational Health and Safety
(OH&S) aspects.
 Formulation and maintenance of OH&S Management programmes for continua l
improvement;
 Periodic review of OH&S Management System to ensure its continuing suitability,
adequacy and effectiveness;
 Communication of OH&S Policy to all employees and interested parties.
 Fig. Tap Changer

WORKING OF
ON LOAD TAP CHANGER (OFF CIRCUIT)
 (8) AN INTRODUCTION TO ON LOAD TAP CHANGER
A tap changer is a connection point selection mechanism along a power transformer winding
that allows a variable number of turns to be selected in discrete steps. A transformer with a
variable turn ratio is produced, enabling stepped voltage regulation of the output. The tap
selection may be made via an automatic or manual tap changer mechanism.

VOLTAGE CONSIDERATION
If only one tap changer is required, manually operated tap points are usually made on the high
voltage (primary) or lower current winding of the transformer to minimize the current handling
requirements of the contacts. However, a transformer may include a tap changer on each
winding if there are advantages to do so. For example, in power distribution networks, a large
step-down transformer may have an off-load tap changer on the primary winding and an on-
load automatic tap changer on the secondary winding or windings. The high voltage tap is set
to match long term system profile on the high voltage network (typically supply voltage
averages) and is rarely changed. The low voltage tap may be requested to change positions
multiple times each day, without interrupting the power delivery, to follow loading conditio ns
on the low-voltage (secondary winding) network.
To minimize the number of winding taps and thus reduce the physical size of a tap changing
transformer, a 'reversing' tap changer winding may be used, which is a portion of the main
winding able to be connected in its opposite direction (buck) and thus oppose the voltage.

CLASSIFICATION OF TAP CHANGING

OFF-CIRCUIT DESIGNS (NLTC OR DETC):

Also called No-Load Tap Changer (NLTC), off-circuit tap changer, or De-Energized Tap
Changer (DETC).
In low power, low voltage transformers, the tap point can take the form of a connection
terminal, requiring a power lead to be disconnected by hand and connected to the new termina l.
Alternatively, the process may be assisted by means of a rotary or slider switch.
Since the different tap points are at different voltages, the two connections cannot be made
simultaneously, as this would short circuit a number of turns in the winding and produce
excessive circulating current. Consequently, the power to the device must be interrupted during
the switchover event. Off-circuit or de-energized tap changing (DETC) is sometimes employed
in high voltage transformer designs, although for regular use, it is only applicable to
installations in which the loss of supply can be tolerated. In power distribution networks,
transformers commonly include an off-circuit tap changer on the primary winding to
accommodate system variations within a narrow band around the nominal rating. The tap
changer will often be set just once, at the time -of installation, although it may be changed later
during a scheduled outage to accommodate a long-term change in the system voltage profile.
ON-LOAD DESIGNS (OLTC):

Also called on circuit tap changer or On Load Tap Changer (OLTC).

For many power transformer applications, a supply interruption during a tap change is
unacceptable, and the transformer is often fitted with a more expensive and complex on-load
tap-changing (OLTC, sometimes LTC) mechanism. On-load tap changers may be generally
classified as either mechanical, electronically assisted, or fully electronic.

Fig. On Load Tap Changer

 (9) ON-LOAD TAP-CHANGERS FOR POWER TRANSFORMERS
Power transformers equipped with on-load tap- changers (OLTCs) have been the main
components of electrical networks and industrial applications for nearly 90 years. OLTCs
enable voltage regulation and/or phase shifting by varying the transformer ratio under load
without interruption.

From the start of tap-changer development, two switching principles have been used for load
transfer operation – the high-speed resistor-type OLTCs and the reactor-type OLTCs.

Over the decades both principles have been developed into reliable transformer components
which are available in a broad range of current and voltage applications. These components
cover the needs of today’s network and industrial process transformers and ensure optimal
system and process control.

The majority of resistor-type OLTCs are installed in- side the transformer tank (in-tank
OLTCs) whereas the reactor-type OLTCs are in a separate compartment which is normally
welded to the transformer tank.

This paper mainly refers to OLTCs immersed in trans- former mineral oil. The use of other
insulating fluids or gas insulation requires the approval of the OLTC manufacturer and may
lead to a different OLTC de- sign, as shown in chapter.

SWITCHING PRINCIPLE

The OLTC changes the ratio of a transformer by adding or subtracting to and turns from either
the primary or the secondary winding. The transformer is therefore equipped with a regulating
or tap winding which is connected to the OLTC.

The principle winding arrangement of a 3-phase regulating transformer, with the OLTC located
at the wye-delta-connection in the high volt- age winding. Simple changing of taps during an
energized status is unacceptable due to momentary loss of system load during the switching
operation. The “make (2) before break (1) contact concept”, shown in Figure 4, is therefore the
basic design for all OLTCs. The transition impedance in the form of a resistor or reactor
consists of one or more units that bridge adjacent taps for the purpose of transferring load from
one tap to the other without interruption or appreciable change in the load current. At the same
time they limit the circulating current (IC) for the period when both taps are used. Normally,
reactor-type OLTCs use the bridging position as a service position and the re- actor is therefore
designed for continuous loading. The voltage between the taps mentioned above is the step
voltage, which normally lies between 0.8 % and 2.5 % of the rated voltage of the transformer
 Fig switching sequence of OLTC
With a reversing change-over selector the tap winding is added to or subtracted from the main
winding so that the regulating range can be doubled or the number of taps reduced. During this
operation, the tap winding is disconnected from the main winding. The greatest copper losses
occur, however, in the position with the minimum number of effective turns. This reversing
operation is realized using a change-over selector which is part of the tap selector or of the
selector switch (arcing tap switch). The rated position is normally the mid position or neutral
position.

Fig. Switching sequence of tap selector – diverter switch (arcing switch)

The double reversing change-over selector avoids the disconnection of tap winding during the
change-over operation. In phase-shifting transformers this apparatus called the advance-retard
switch.

Which of these basic winding arrangements is used in each individual case depends on the
system and operating requirements. These arrangements are applicable to two winding
transformers as well as to autotransformers and to phase-shifting transformers where the tap
winding and therefore the OLTC is inserted in the windings (high-voltage or low- voltage side)
depends on the transformer design and customer specifications. For regulated
autotransformers, fig. 8 shows various circuits. The most appropriate scheme is chosen with
regard to regulating range, system conditions and/or requirements, as well as weight and size
restrictions during transportation. Autotransformers are always wye-connected.

a) Three pole line-end arrangement

b) One and two pole line-end arrangement

c) Three pole mid-winding arrangement

I neutral end regulation (fig. 8 a) may be applied with a ratio above 1 : 2 and a moderate
regulating range up to 15 %. This operates with variable flux. a scheme shown in fig. 8 c is
used for regulating high voltage for low voltage U2 regulation, the circuits fig. 8 b, 8 d, 8 e and
8 f are applicable. The arrangements fig. 8 e and 8 f are two core solutions. Circuit fig. 8 f
operates with variable flux in the series transformer, but it has the advantage that a neutral end
OLTC can be used. In the case of arrangement according to fig. 8 e, the main and regulating
transformers are often placed in separate tanks to reduce transport weight. At the same time,
this solution allows some degree of phase shifting by changing the excitation connections
within the intermediate circuit. Over the last few years, the importance of phase- shifting
transformers used to control the power flow on transmission lines in meshed networks has been
steadily increasing .The fact that IEEE provides a “guide for the Application, specification and
Testing of Phase-shifting Transformers“ proves the demand for These transformers often
require regulating ranges which exceed those normally used. To achieve such regulat ing
ranges, special circuit arrangements are necessary. Two examples are given shows a circuit
with direct line-end regulation, fig. 10 an intermediate circuit arrangement illustrates very
clearly how the phase-angle between the voltages of the source and load systems can be varied
by the OLTC position. Various other circuit arrangements have been implemented.
 (10) DESIGN CONCEPT OF ON LAOD TAP CHANGER

Apart from tap selection, the most important task of an OLTC is the break function or current
(load) transferring action. After transferring the current, the contact which “breaks” must be
capable of withstanding the recovery voltage. The required switching capacity (the product of
switched current and recovery voltage) for a specific contact in an OLTC is based on the
relevant step voltage and cur- rent but is also determined by the design and circuit of the OLTC.
The switching capacity itself is primarily a function of the contact design, contact speed and
arc-quenching agent.

Historically, most power transformers use mineral oil as a cooling and insulation medium. The
development of OLTCs toward the present “state of the art” de- signs also focused on
transformer oil. Apart from the insulation properties of the transformer oil, the arc- quenching
behavior of the switching contacts deter- mined the design and size of “oil-type” OLTCs.

In an oil-type OLTC, the OLTC is immersed in trans- former oil and switching contacts make
and break current under oil. This conventional OLTC technology has reached a very high level
and is capable of meeting most of the transformer manufacturers’ requirements. This applies
for all the voltage and power fields today, which will probably remain unchanged in the
foreseeable future.

Along with the increase in demand for electrical energy in metropolitan areas, the necessity for
installing transformers in buildings creates a need for regulating transformers with reduced fire
hazards. In addition to this and with respect to the prevention of water pollution, regulating
transformers that do not require conventional mineral oil as an insulating or switching medium
are preferable.

Apart from gas-immersed transformers, which are mainly used in Japan, dry-type transforme rs
and trans- formers with alternative insulating fluids meet these requirements, which are
increasingly being requested.

Conventional tap-changers are not really suitable for this kind of regulating transforme rs,
because the use of mineral oil as a switching medium is – for the rea- sons mentioned above –
not desirable and would also require technically complex and expensive overall solutions.

In addition, worldwide deregulation in the electric industry is still a concern. As part of this
market, mechanisms have been encouraged to price transmission services and encourage both
generation and trans- mission investment.
OIL-TYPE OLTCS – OILTAP

The OLTC design that is normally used for higher ratings and higher voltages comprises a
diverter switch (arcing switch) and a tap selector. For lower ratings, OLTC designs in which
the functions of the diverter switch (arcing switch) and the tap selector are combined in a
selector switch (arcing tap switch) are used.

With an OLTC comprising a diverter switch (arcing switch) and a tap selector, the tap-change
operation takes place in two steps. The next tap is first preselected by the tap selector at no
load. The diverter switch then transfers the load current from the tap in operation to the
preselected tap. The OLTC is operated by means of a drive mechanism. The tap selector is
operated by a gearing directly from the drive mechanism. At the same time, a spring energy
accumulator is tensioned, which operates the diverter switch – after release at a very short time
interval – independently of the motion of the drive mechanism. The gearing ensures that this
diverter switch operation always takes place after the tap preselection operation has finis hed.
The switching time of a diverter switch is between 40 and 60 Ms with today’s designs. During
diverter switch operation, transition resistors are inserted which are loaded for 20–30 Ms, i.e.
the resistors can be designed for short-term loading. The amount of resistor material required
is therefore relatively small. The total operation time of an OLTC is between 3 and 10 seconds,
depending on the respective design.

A selector switch (arcing tap switch) as shown in carries out the tap-change in one step from
the tap in service to the adjacent tap. The spring energy accumulator, wound up by the drive
mechanism actuates the selector switch sharply after releasing.

Fig. oil type OLTC

 (11) DESCRIPTION OF EQUIPMENTS
TAP CHANGER TYPE M

The OILTAP® M on-load tap-changer is used to vary the ratio of oil-immersed transformers
under load. In general it is designed for network transformer as well as industrial transformer
applications. The tap-changers comprise a diverter switch and a tap selector in a single
column design and represent the most recent state of technology. The tap-changers offer both
transformer manufacturer and user a great number of essential advantages.

Fig. OLTC type M

VERSATILITY:

– three-pole design for neutral application at 350 A, 500 A and 600 A ratings for
three-phase wye-connected windings
– single-pole designs at 350 A, 500 A, 600 A, 800 A, 1200 A and 1500 A
ratings for auto connected windings or single-phase transformers
– available with ±9, ±11, ±13, ±15, ±17 steps – insulation to ground and tap
selector size can be selected independently of one another
 – convenient for bell-type tank installation – additional devices for potential tie-
in of tap winding during change-over operation of the change-over selector
(tie-in resistors, potential contact)

COMPACTNESS:

– high speed transition resistor type diverter switch with arc extinction at the
first current zero
– diverter switch uses snap-action mechanics by energy accumulator mounted
directly on the diverter switch
– minimum possible tap selector dimensions because four available sizes ensure
matched impulse voltage with stand ability
– radial dimensions of the tap selector are reduced by special shaping of all parts
on high potential, distances between tap selector bars determined by actual
voltage stress – optimised integration of the change-over selector into the fine
selector contact circle

ROBUSTNESS– LONG LIFE:

– rapid tap change operation, low thermal stress on the transition resistors
– diverter switch arcing contacts made of tungsten-copper alloy at 500 A and
above
– –simple tap selector design, effective contact cooling, high short-circuit with
stand ability
– tap selector gear with steady torque during the tap changer operation

EASY TO INSTALL – COST SAVING:

– oil-immersed installation of the entire tap-changer in the transformer main tank

– simple to connect
– drive shaft and pipe connections easy to orientate
– straight forward coupling to motor drive unit

REDUCED MAINTENANCE:

– long contact life

– quick and easy to disassemble diverter switch insert
– simple to adjust and control
– oil suction pipe built-in
– diverter switch contacts easy to replace
MOTOR DRIVE UNIT

An on-load tap-changer is normally used in power transformers in an electric grid, where its
function primarily is to keep a constant voltage out from the transformer. Some on-load tap-
chargers are used in transformers where their function is to control the power of the transfor mer
by regulating the voltage. The on-load tap-changer can be described as a mechanical switching
device that will change the turn ratio in the transformer without interrupting the load current.
This makes it possible to keep a constant voltage out from the transformer and to compensate
for variations in the load.

A common on-load tap-changer generally consists of a motor drive unit, an axis system, a
diverter switch with a housing, and a selector mounted under the diverter switch. Such an on-
load tap-changer is named a diverter switch type. Another on-load tap-changer, wherein the
selector and the diverter switch are merged into the same unit is named a selector switch type.

The main objective of an electric motor drive unit is to drive the connected on-load tap-changer
to a higher or a lower tap of a transformer. Electric motor drive units for tap changers are rather
complex and the cost for their production and assembly- is considerable. Further, electric motor
drive units are to a large extent order designed, with a customer requirement as basis, which
further increases cost for their production and assembly.

Fig. Motor assembly for OLTC

BENEFITS OF MOTOR DRIVE UNIT:

An object of the present invention is to provide an electric motor drive unit for tap-changers
which is adaptable to different customer requirements.

The invention is based on the realization that by providing an on-load tap-changer with an
electric motor drive unit at a minimum the following advantages are achieved:

• Reduced lead time in production

• Flexibility for late order changes

• Service friendly design

• Reduced tap-changer motor drive cost

PROTECTIVE RELAYS:

A relay is automatic device which senses an abnormal condition of electrical circuit and
closes its contacts. These contacts in turns close and complete the circuit breaker trip coil
circuit hence make the circuit breaker tripped for disconnecting the faulty portion of the
electrical circuit from rest of the healthy circuit. The protective relay is designed to protect
the on-load tap-changer and the transformer during a malfunction within the on-load tap-
changer or the selector switch oil compartment. It trips when the specified oil flow speed
between the on-load tap-changer head and the oil conservator is exceeded. The protective
relay must be connected so that the transformer is immediately isolated from the power when
the protective relay trips.

Fig Protective Relay

MOUNTING OF DRIVE SHAFT AND BEBEL GEAR UNIT

Due to the special arrangement of the tap-changer phases in three columns, the horizontal drive
shaft must be mounted between the three tap-changer heads above the tank cover. Since a
swivelling of the upper gear unit will initiate a switching action, make sure that the adjustment
position of the diverter switch is re- gained after the alignment of the gear units.

Fig Drive Shaft and Bebel Gear

FOR THIS PURPOSE PROCEED AS FOLLOWS:

 Check that the operating positions of all columns are identical (tap-changer head,
inspection window). Each one of the one-phase OLTCs must be in the adjustment
position.
 Turn the upper gear unit of the tap-changer heads into the desired installation position
and fix them there (tighten thrust collars and tab-lock the screws).
 Take note of the arrow on the drive shaft flange below the punched serial number. The
direction of the arrow indicates the rotation sense when crank- ing the motor drive
clockwise and must be identical on all gear units.
 Operate the tap-changer poles separately by one step by rotating the trunnions counter -
clockwise until the diverter switch operates once. Check coincidence of operating
positions of all tap-changer heads.
 Mount the horizontal drive shaft between the tap- changer heads.
 Return the OLTC set that is all tap-changer poles together, into the adjustment position.
The adjustment position is reached by turning the drive shaft in clockwise direction.
 Check simultaneous operation of all diverter switches. Check coincidence of position
of all tap- changer heads and the motor drive unit.
 Mount the vertical drive shaft.

Make sure that bevel gear serial number and on-load tap-changer serial number are identica l.
The horizontal drive shaft must be in proper alignment with the trunnion in the tap-changer
head. After loosening the thrust collar (6 bolts M8, was. 13) the upper gear unit can be swivelled
(fig. 39). After adjusting the upper gear unit, the thrust collar must be re-tightened (max. torque
15 Nm). Tab-lock the screws. In case of bevel gears in special design and intermediate bearings
of the vertical or horizontal drive shaft above instructions apply analogously.

Square shafts, coupling brackets, coupling bolts, screws, nuts and lock tabs are made of
corrosion-proof steel. We recommend, however, to apply the same outside coating here as to
the transformer tank. The square shafts and the guard plate for the footstep protection for the
horizontal drive shaft at the trans- former cover are supplied in oversize (various standard
lengths). These parts must be cut to the required size before mounting. Finally equalize the
rotation lag between on-load tap- changer and motor drive unit will be completed.

Fig. Bebel Gear Assembly

 (12) INSTALLATION OF OLTC
MOUNTING FLANGE

To mount the tap-changer head to the transformer cover a mounting flange is necessary. This
mounting flange should meet the requirements of the tap-changer head gasket surface.

Fig. Drawing for mounting tap changer

To position the thread studs (M12, max. length = 45 mm) we recommend the use of a drilling
template. If requested, the drilling template will be supplied without charge with the first on-
load tap-changer type R.

Fig. Drilling template

ATTACHMENT OF THE TAP-CHANGER HEAD TO THE TRANSFORMER
COVER

The diverter switch oil compartment is lowered through the cover aperture (= mounting flange)
of the trans- former. The tap-changer head is attached to the mount- ing flange by means of
bolts. Then, the tap selector is fastened to the diverter switch oil compartment.

PROCEED AS FOLLOWS:

 Place the diverter switch oil compartment on a level surface.

 Clean sealing surfaces of mounting flange and tap- changer head.
 Put an oil-proof gasket on the mounting flange of the transformer cover.
 Lift the diverter switch oil compartment by hooking up the tap-changer head. Lower
the oil compartment cautiously into the mounting flange. Take care of screening rings
(with Um ≥ 170 kV only). 5. Check position of tap changer head.
 Attach the tap-changer head to the mounting flange with bolts.

NOTE:

Remove the blocking plate from the coupling (shown in figure below) of the oil compartment
bottom.

Fig Removal the blocking plate

MOUNTING THE TAP SELECTOR AND THE DIVERTER SWITCH OIL

COMPARTMENT

Raise the tap selector to the oil compartment and attach. At the same time the mechanic a l
coupling for the tap selector drive has to be performed. Finally, connect the tap selector
connecting leads to the diverter switch oil compartment.
PROCEED AS FOLLOWS:

 Put the tap selector down on a level surface. Get ready 4 lock nuts M12 with washers.

NOTE:

Remove the blocking strip from the tap selector coupling. The coupling must not be displaced
afterwards

Fig. Removal of blocking strip

 2. Put the tap selector on an appropriate lifting device. Remove the ring nuts.
 Raise the tap selector to the diverter switch oil compartment. Be sure that tap selector
connecting leads clear the diverter switch oil compartment and remain undamaged.
 Position coupling parts and attachment points of tap selector and oil compartment to
match properly.
 Raise the tap selector to its final height.

Fig. Raising of tap selector

  Bolt tap selector attachment points to the oil compartment bottom: 4 lock nuts M
12/w.s.19, washers, maximum torque 65 Nm.
 Remove the wooden support from the laterally attached change-over selector.

CONNECTION OF THE TAP SELECTOR CONNNECTINGS LEADS TO THE

DIVERTER SWITCH OIL COMPARTMENT

OLTCs R III 1200 and R I 3000/3600:

6 connecting leads to oil compartment terminals according to Each one attached by 1 bolt
M12 (w.s.19) lock nut and screening cap, torque 80 Nm.

Fig. 6 connecting leads to oil compartment terminals

OLTC R I 2002/2402:

4 connecting leads to oil compartment terminals according to Each one attached by 1 bolt M12,
lock nut and screening cap, torque 80 Nm.

Fig. 4 connecting leads to oil compartment terminals

INSTALLATION OF THE ON-LOAD TAP CHANGER INTO THE BELL-TYPE
TANK

Firstly, lift the on-load tap-changer into the supporting structure and connect it to the tap
winding. The OLTC must be attached to the supporting structure in such a way that it cannot
be displaced. The supporting flange is provided with through-holes which allow it to be fixed
to the supporting structure. It is advisable to put spacer blocks temporarily between
supporting structure and supporting flange and to remove them before the bell type cover is
set up.

ASSEMBLY OF DIVERTER SWITCH OIL COMPARTMENT AND TAP

SELECTOR, ATTACHMENT OF TAP SELECTOR CONNECTING LEADS:

The assembly of diverter switch oil compartment and tap selector as well as the connection
of tap selector connecting leads has to be carried out according to section Lift the assembled
on-load tap-changer, into the supporting structure. Make sure that the on-load tap-changer is
in proper mounting position and fasten it there safely.

Prior to setting up the bell-type tank the tap-changer head must be removed from the on-load
tap-changer.

1. For this purpose, open the tap-changer head cover (24 hexagonal head screws M10,
w.s.17, with lock washers).

2. Take care of the cover gasket.

3. Remove the position indicator dial.

Fig. Removal the clip from the shaft end

4. Take note of the red-marked area not covered by the supporting plate of the diverter switch
unit.

Fig. -marked area not covered by the supporting plate

5. Remove the fixing nuts of the supporting plate (4 nuts M8, w.s.13, lock washers,

Fig. Remove the fixing nuts of the supporting plate

6. Withdraw the diverter switch unit carefully from the oil compartment. Keep the diverter
switch unit in a vertical position.

Fig. Withdrawing of the diverter switch unit

7. Remove the suction pipe. The pipe connection has to be withdrawn from within the tap-
changer head. Take care of O-rings.

Fig. withdrawing of pipe connection

8. Unscrew the remaining nuts in the tap-changer head, 17 nuts M8, w.s.13. lock washers.
Lift off the tap-changer head from the supporting flange. Take care of the gasket.

Fig. Unscrewing of the remaining nuts in the tap-changer

MOUNTING THE BELL-TYPE TRANSFORMER COVER

1. Before mounting the bell-type transformer cover clean the sealing surface of the oil
compartment supporting flange. Place the gasket onto the flange. Withdraw the spacer blocks.

Fig. Placing of the gasket onto the flange

2. Lift the bell-type cover over the transformer active part and lower it to its final position.
3. Before mounting the tap-changer head clean the sealing surfaces (bottom of tap-changer
head, mounting flange). Put an oil-resistant gasket on the mounting flange.

4. Place the tap-changer head on the mounting flange. Check the mounting position of the tap-
changer head by means of 2 adjusting bolts and the marks of the supporting flange and tap-
changer head which allow assembly in the correct position only. Depending on the final height
adjustment leave a clearance of 5 to 20 mm between tap-changer head and supporting flange.

Fig. Place the tap-changer head on the mounting flange

5. Lift the on-load tap-changer slightly by means of the lifting traverse. Make sure that all
supporting flange studs easily slide through the fixing holes of the tap- changer head.

Fig. lifting of tap changer

 (13) TEST PERFORMED ON OLTC
TRANSFORMER RATIO TEST

We recommend to ratio-meter the transformer with a low AC voltage before drying. To operate
the drive shaft in the tap-changer head a short tube of nominal width 25 mm with an insert
coupling bolt of 12 mm dia. together with a hand wheel or a hand crank may be used.

In case of OLTC set 3 x RI2002 ... 3600 all three tap- changer heads have to be coupled by the
horizontal drive shafts.

When using an ED, 16.5 drive shaft revolutions of the tap-changer drive shaft are required for
one tap-change operation. The diverter switch action can be heard distinctly.

Fig. Tap changer head cover

To operate the change-over selector a higher torque is necessary. The end positions shown on
the connection diagram supplied with the delivery must never be overrun. It is therefore
necessary to check the operating position through the inspection glass in the tap-changer head
cover. Keep the number of tap-change operations to a minimum as long as the on-load tap-
changer has not been immersed in oil. After the transformer ratio test the on-load tap-changer
has to be set back to the adjustment position in which it was delivered by MR. The position is
indicated in the connection diagram delivered with the equipment.

NOTE:

If the transformer is to be vapour phase dried in its own tank, open the kerosene drain plug.
OPERATIONAL TESTS

Before applying voltage to the transformer check the mechanical operation of on-load tap-
changer and motor drive.

For these test operations the on-load tap-changer has to be run through the complete operating
cycle. Make sure that in each operating position the indicators of motor drive and on-load tap-
changer (tap- changer head) read the same position. Make sure that in both end positions the
electrical and mechanical limit stops function automatically.

Misalignment between on-load tap-changer and motor drive unit exists, if on-load tap-changer
and motor drive unit show different operating positions. Misalignment of coupling between
on-load tap- changer and motor drive unit leads to severe damage of on-load tap-changer and
transformer, if operation is continued. The transformer must not be taken in operation.
 (14) TRANSPORTATION AND OPERATION OF OLTC
TRANSPORT TO THE OPERATING SITE

If the transformer is to be transported without the motor drive unit, set the motor drive to the
adjustment position and uncouple. To remount the motor drive unit follow the instructions.

Install this by-pass tube between pipe connections E2 and Q of the tap-changer head. For short
time conditions of 2 to 4 weeks without oil conservator, lower the oil level by approx. 5 litres.

If the transformer is to be transported or stored without oil filling, drain the oil of the on-load
tap-changer completely.

The interior of the on-load tap-changer should be conserved and protected in the same way as
the transformer itself (nitrogen-sealing).

If a prolonged stand-by period is expected, the heater of the motor drive unit must be connected
to the suitable power supply.

Note:

If the transformer is filled with oil but stored or trans- ported without oil conservator, a bypass
tube must be installed between the interior of the tap changer and the transformer tank to
compensate the static pressure caused by expansion of oil.

Caution:

Do not operate the motor drive unit while the on-load tap-changer is uncouple.

PUTTING INTO SERVICE AT THE OPERATING SITE

Before putting the transformer into service, operational tests of on-load tap-changer and motor
drive have to be performed. At the same time check the function of the protective relay. Loop
in signalling contact for undershooting the minimum oil level in the on-load tap-changer oil
conservator in the on-load tap-changer tripping circuit. Make sure that the circuit breakers
switching off the transformer operate when the test push button »OFF« is pressed. Be sure that
they energize the transformer only after push button »IN SERVICE« of the protective relay has
been pressed. After the transformer has been energized, tap-change operations under load can
be performed. Gas accumulating under the cover of the tap-changer head will cause minor oil
displacement and/or escape via the oil conservator.

NOTE:

The protective relay has to be inserted into the trip- ping circuit of the circuit breakers so that
energization of the protective relay switches off the trans- former immediately (see Operating
Instructions No. 59 for protective relay RS 2001).
 (15) SUPERVISION AND INSPECTION
SUPERVISION DURING SERVICE, FAILURES

It is only necessary to inspect the tap-changer head, the protective relay and the motor drive
unit occasionally.

PAY SPECIAL ATTENTION TO:

•oil tightness of sealings of the tap-changer head, the protective relay and the pipe connections,

•sealings at the motor drive housing,

•proper function of the electrical space heater inside the motor drive unit,

•the condition of the control devices in the motor drive unit.

NOTE:

Damage to the on-load tap-changer due to not enough oil in the oil conservator of the on-load
tap- changer! Actuation of the on-load tap-changer with too little oil in the on-load tap-
changer’s oil conservator may cause damage to the on-load tap-changer! Make sure that the
contact for signaling the falling below the minimum oil level in the on-load tap- changer’s oil
conservator was looped through to the tripping circuit of the circuit-breaker and that the circuit-
breaker will immediately de-energize the transformer when the oil has fallen below this
minimum oil level in the oil conservator.

WARNING:

If the protective relay operates, do not reset until the on-load tap-changer and the transfor mer
have been checked. For this purpose also withdraw the diverter switch unit and check it
according to our Inspection Instructions. Proceed in detail according to our Operating
Instructions No. 59 for the protective relay RS 2001.

Before returning to energized operation, make sure that the cause of the trouble has been
corrected and that the on-load tap-changer and the transformer are free of damage.

Never reconnect the transformer without prior checking. Continued operation of the on-load
tap changer can result in severe damage of on-load tap- changer and transformer.

INSPECTIONS

In general, the inspection can be carried out by qualified and MR-trained personnel within one
day, provided it is well prepared and organized.

We strongly recommend to have inspections performed by our Technical Service. This

guarantees a professional performance including all the latest updating measures.

Inquire for spare parts when preparing an inspection which will not be carried out by MR
personnel (please indicate OLTC number and number of operations).
The number of tap-change operations determining the inspection intervals indicated in table II
and table III are figures based on experience with oil qualities normally used.

The tap selector of the on-load tap-changer is generally maintenance- free. In special cases,
however, if OLTCs are used in industrial transformers where high operating numbers are to be
expected, our technical service department must be contacted after about 1,000,000 operations.
The diverter switch insert of the OLTC is to be replaced after 800,000 operations.

If the number of operations per year is 15,000 or higher, the use of our oil filter plant type
OF100 with paper filter insert is recommended. The use of our oil filter plant type OF100 with
combination filter insert is obligatory for OLTC type R with insulation to ground Um < 245
kV. Filtering of switching oil allows to extend the inspection intervals.

The user should regularly test the transformer insulating oil according to the relevant standards.

If inspection has not been performed by MR-personnel, please give us your report for data
collecting purposes.

NOTE:

The tap-changing equipment must be inspected at regular intervals to maintain a high level of
operating reliability.

CAUTION:

Inspections of the tap-changer equipment are obligatory. Disregarding the inspection

intervals endangers the trouble-free operation of on-load tap- changer and transformer.
 CONCLUSION
This report clearly replicates the tremendous growth of a company which continuo us ly
renovated its technology to contribute not only in the infrastructure building in India but also
of the world.

It is an asset for our country to have such a public sctor industry which has fulfilled the dream
of our first Prime Minister Sh. Jawaharlal Nehru by operating in 65 countries and making it
to global.

The vision and mission of this company are successful can be adjudged with the faith of the
stake holders in this company.

BHEL Jhansi although a smaller unit in comparision to otherunits of BHEL, is a very

productive one with the manufacturing of the electric locomotives, power transformers etc.

The work load here can be accessed from the fact that the order of the locomotives has forced
the company to shift its Bus Duct section to other unit of BHEL.

In future also the company is having orders of metro coaches and this clearly shows why this
company is still recession proof.
 REFERENCE
 Dr. Dieter Dohnal, Electrical Machines

 G. Spence, A. C. Hall, “On-load Tap-changers Current Experience and Future

Development; Users Experience and Perspective,” IEEE European Seminar on
Developments On-Load Tap Changers: Current Experience and Future, 9 November
1995.
 M. Runde et al, “Acoustic Diagnosis of high voltage circuit-breakers,” IEEE
Transactions on Power delivery, Vol.7, No.3, July 1992.

 V. Demjanenko et al, “A noninvasive diagnostic instrument for power circuit breakers,”

IEEE Transactions on Power delivery, Vol.7, No.2, April 1992.

 S. Tenbohlen, M. Stach et al., “Experience-Based Evaluation of Benefits of On-line

Monitoring Systems for Power Transformers”, CIGRE Session 2002, paper 12-110,
Paris, 2002.
 A case study Rupali Vibhute" ,R.M.Holmukhe2 Mr.P.S. Chaudhari",
Mr.T.S.Hasarmani4 1.4postGraduate Student, Electrical Engineering Department,
2Assistant Professor, Electrical Engineering Department, Bharati Vidyapeeth Deemed
University, College of Engineering, Pune, India 3Scientist ,DRDO, Pune

 www.reinhausen.com

 www.iitm.in