The EnergisingTransformers

Solution

Power

ISO 14001ISO 9001

U K A SU K A SU K A SU K A SU K A S

attitude, a fusion of experienceand expertise in the field ofapplied energy, extensive R & D,advanced technology, dedicatedworkforce, superior manufacturingskills, exacting standards ofquality and diverse and distinctivecompetencies that converge,Crompton Greaves offers acomprehensive portfolio ofproducts and services forGeneration, Transmission,Distribution and Utilization ofpower in various applications. Itspresence is well established andwidespread, notably in theUtilities, Industry, Agriculture,Transportation, Informatics,Telecommunication and LifestyleProducts.

Crompton Greaves promotes ahigh level of Research andDevelopment activities to maintaina technological lead andcompetitive advantage. R & Doperations are structured toinitiate a techno-active responseright through the company, gettingresearch out of the labs in to theproducts. Numerous awards andISO 9000 certifications haveaccredited the exacting standardsof quality management.

Today, Crompton GreavesInternational Operations arespread over all the continents inthe world to become the largestfrom India in each segment ofTransformers, Switchgear,L.V. Controlgear, Motors andAlternators, Pumps and Fans.

As the new millennium consumersplug-in to a switched-on future,Crompton Greaves, a member ofthe B. M. Thapar Group andInvensys plc., will continue to playan electro-dynamic role…engineering the right solutions… making a difference to life andthriving in an increasingly wiredworld.

ExpressionsofPower

Crompton Greaves Ltd.,established in 1937, has witnessedover six decades of unparalleledgrowth to have current sales ofover IRs 16 Billion (US $ 330Millions). With an electrifying

Power Systems • Industrial Systems • Consumer Products • Informatics & Telecom

Bhopal Plant

.... for over 60 years!

EnergisingSolutions

1

Crompton Greaves kicked offthe Transformers operation withtheir first supply to the US Armyover 60 year’s back! Initialtechnology was from BrushTransformers and HawkerSiddeley Power Transformers,both from U.K. and then, fromWestinghouse ElectricCorporation, U.S.A. forTransformers upto 400 kV tomatch growing volumes andchanging internationalrequirements. Havingcommissioned over 120 MillionkVA in Transformers, CromptonGreaves are today the leadingmanufacturer of Transformersand Reactors, with a widerange, for all critical applications.

To sustain the growing demandof Transformers, CromptonGreaves commissioned a newintegrated Plant at Gwalior (T2)spread over 20,000-sq. m. in1991 and yet another at Bhopal(T3), spread over 30,000-sq. m.in 1995. A new Plant forAmorphous Core Transformers,having 1,500 kVA capacity wascommissioned in 2001. Withenhanced capacity of 18,500MVA now, Crompton Greaveshave successfully spearheadedentry in to the most demandingmarkets of the world.

Mumbai Plant

Transformer Design Solutions

Gwalior Plant

Bhopal Plant - Amorphous Core Transformers

2

Crompton Greaves have thecapability to producetransformers from 400 kVA to900,000 kVA (in a Bank), 3.3 kVto 500 kV class for variousapplications and conforming toIS, IEC, EN, AS, BS, ANSI andother international standards.

320 MVA, 16/230 kV, GSU Transformer,AES Haripur, Bangladesh

POWER TRANSFORMERS

• Generator Transformers forThermal, Nuclear, Hydro andGas Generating Stations.

• Upto 450 MVA, 500 kVclass, three phase.

• 900 MVA, 500 kV in a bank.

• Auto Transformers for step-upand step-down

• 500 MVA, 500 kV class,three phase.

• 900 MVA, 500 kV class in abank.

• Reactors, Series and Shunt,upto 80 MVAr, 500 kV class.

• Multi Winding Auto andGenerator Transformers

77/96/110 MVA, 11.5/115 kV, GSU Transformer at Rojana & Saha Co-Gen, Thailand

180 MVA, 14.7/230kV Transformer

Cast Resin Transformer

Marshalling Box

µp based temperature and voltagecontrol

Fibre Optic Control Panel

SPECIAL TRANSFORMERS

• Arc and Induction FurnaceTransformers upto 40 MVA,33kV, up to 60 kA Currentapplication.

• Trackside Transformers 31.5MVA, 25 kV AC, single phase.

• Locomotive Transformersupto 5400 kVA, 25 kV AC.

• Thyristor Duty Transformers.

• Package Substations upto2000 kVA.

• Earthing and AuxiliaryTransformers.

SPECIAL FEATURES - OPTIONAL

• Sealed Tank construction toANSI standards.

• Noise level of upto 50 dB(A).

• RTCC Panels with PLCs forSCADA compatibility.

Ž Fibre Optics for direct hotspot measurement.

• Intelligent on-line monitoringsystems.

• Nitrogen based fireprotection systems.

• Compliance to EU norms.

DISTRIBUTIONTRANSFORMERS

• Oil Cooled Transformers, 500kVA to 10,000 kVA, upto 33kV.

• Dry Transformers upto 2500kVA. 33kV. (Cast Resin andResin Impregnated)

• Amorphous CoreTransformers.

• Unitised Substations.Unitised Substation

3

RTCC Panel

Oil Filled Distribution Transformer

Transformer Engineering Centre at Mumbai Plant

TRANSFORMERS,TECHNOLOGY

Crompton Greaves haveabsorbed world classtechnologies throughcollaborations for built intotal reliability.

• Brush Transformers, U.K.

• Hawker Siddeley PowerTransformers, U.K.

• Westinghouse, U.S.A. for FoilTechnology, Distribution andPower Transformers andShunt Reactors upto 500 kVclass.

• GE, U.S.A. for AmorphousCore Transformers

• ABB, Sweden for LocomotiveTransformers.

Design technology incorporatesthe following state of the arttechniques and software tocomply with the ever demandingcustomer and systemintegration needs and the latestmanufacturing techniques .

• 2D and 3D Finite ElementMethod (FEM) analysis forelectrostatic andelectromagnetic distribution

• MAGNET forelectromagnetics.

• IDEAS and ANSYS forstructural designs.

• ANSYS for seismic analysis.

• AutoCAD and special add-onsoftware for components, partsand their quick integration in tothe final Product.

• Simulation techniques fornoise, vibration, thermal, hotspot and seismic analysis.

4

FEM analysis of core assembly

Layout of Dry Type Transformer

Tank under simulation test for vacuumwithstand

3D View of Transformer components

With deployment of well qualifiedEngineers and Technocrats,Crompton Greaves have fullyharnessed long experience inDesign and Software, a corestrength of India, to offerinnovative, reliable and efficientTransformer solutions. Advancedcomputer systems, designtechniques and simulation of thefield conditions contribute to fastproduct development and ensureenhanced reliability – so verycritical for the Transformers.

Structural seismic analysis ofTransformers

Clearance Sphere - design verification

High Speed 'GEORG' CNC Machine

5

Core assembly of 250MVA Generator Transformer

POWER TRANSFORMERS,CORE BUILDING

Transformer Cores are built withCRGO, low loss silicon steellaminations. Use of Hi-B gradeand laser scribed laminationsfor core significantly reduces noload losses and noise levels ascommitted.

New high speed “GEORG” CNCmachines for core slitting andcropping offers stress freelaminations without burrs forfully aligned core building.Special dimpled sheets providespace between laminations formost effective cooling.

The laminations forming themagnetic circuit are assembledon a special core buildingfixture. The Step-Lap or Mitredjoints at the core cornersensure a streamlinedmagnetic flux path.

The core limbs are held withresin bonded glass bands toeliminate limb bolts. Yokes areclamped by solid mild steelplates with yoke studs, ensuringhigh rigidity for withstandingmechanical shocks duringtransportation and shortcircuits. For logistics, five limbcore construction offers reducedheight for large PowerTransformers.

Vertical Winding Machine

POWER TRANSFORMERS,WINDING

Electrolytic Grade Copper orContinuously TransposedConductors (CTC) or EpoxyBonded CTC are used to thedesign requirements. Windingsare made on the vertical orhorizontal winding machineswith great care by well-experienced techno-craftsmenin a dust free (5 microns max.)environment, with positivepressure for superiorreliability. High qualitypre-compressed insulation, preshrunk by a specially designedprocess, ensures long servicestability. Thermally upgradedpaper enables emergencyoverloading beyond nameplaterating, wherever desired.

The winding has axial and radialcooling ducts to ensure effectiveheat dissipation in to the oil andeliminating the hot spots.

For high voltage windings, disccoils with excellent mechanicalstrength are used to take thestresses due to voltage level. Aspecial interleaved or shieldedconstruction offers most uniformvoltage distribution despitesystem transients. Finishedcoils are compressed bypredetermined clamping force ina 200 tons, Isostatic HydraulicPress, for retaining thedesigned geometrical positionof the individual winding.

6

Winding Bay

Reactor Core-Coil Assembly

POWER TRANSFORMERS,CORE-COIL ASSEMBLY

The winding is rigidly supportedby a common pressure ring ofdensified wood at the top andbottom, for precise alignment.Well profiled angled rings areplaced between HV and LVwindings to reduce voltagestress levels. The ends andtapping leads of all the windingsare connected by special extraflexible, insulated coppercables, which are rigidly bracedin position. In oil forced units, oilis circulated inside the windingby specially designed pipes ofinsulated materials.

The core coil assembly is driedto less than 0.5% moisturecontent, by the automatedVapour Phase Drying (VPD)plant of MICAFIL. Highmechanical rigidity is achievedby hydraulic pressing atcalculated force and tighteningall pressure screws. Thecore-coil assembly is put intothe tank with proper locatingarrangements. The tank is thenfilled with hot oil, filtrated byHigh Vacuum Oil Filtration Plantto max. 5 PPM moisturecontent, free of particles above5 microns size and with very lowgas content, under vacuum toensure least exposure toatmosphere.

7

Isostatic Press Autoclave

Micafil VPD Facility

POWER TRANSFORMERS,TANKS

Tanks are built with mild steelplates to withstand full vacuum,conforming to the Internationalstandards. The welder’squalification is done as perASME Section IX. Tanks aredesigned to roll and skid inspecified directions.

Lugs for jacking, lifting andhauling are routinely tested fordye penetration test. Tanks havewelded or bolted top cover. Forlarge units above 50 MVA, belltype construction is available.Tanks are shot blastedto get a surface finish of SA 2.5,coated with zinc rich primer andthen painted. Epoxy orpolyurethane painting and spraygalvanising are optionallyoffered to specific requirementsfor surface finish of the Tank.

The transformer is made readyfor final inspection afterassembly of bushings,conservator, radiators etc.

8

Test Bench

TEST FACILITIES

In addition to the normal routinetest facilities, the followingmajor type test facilities areavailable in-house for typetesting the Transformers to allmajor international standards.

1. Switching and LightningImpulse Test System.

2. Partial Discharge and RadioInterference MeasurementFacilities.

3. Noise Level MeasurementSetup.

4. Temperature Rise Test Plant

5. Dissolved Gas Analyser(DGA) for oil.

6. Harmonic Measurement andAnalysis

7. Linearity Test Set for HVReactors

8. Vibration Test Plant

The Transformer designs areproven for dead short circuits bytests conducted at independent,accredited Short CircuitLaboratories.

Impulse Generator

POWER TRANSFORMERS,QUALITY ASSURANCE

High standards set forprocurement and inputs go a longway to ensure reliableTransformers. Quality is ensuredat source for standard materials,with a qualified and dedicatedSupplier base. Continuousupgradation of Suppliers andclose inspection of incomingmaterials, controllingin-process parameters andthorough inspection and testing ofthe Transformers ensureconsistent high-quality standardsthat Customers have come toexpect from Crompton Greaves Dissolved Gas Analyser for oil

PROCESS CERTIFICATION

All the three manufacturingPlants are certified to ISO 9000-2000 and our Mumbai Plant toISO 14001 standards as well, byBVQI, U.K.. A structured TQMprogramme is in place ensuringcontinuous improvementtowards world class qualitystandards. The qualityassurance systems are backedby a strong in-house R & Dcontinuously working to upgradeand ensure total system reliability.

With SAP/R3 implementation,the internal processes arefurther sharpened to provideeffective Transformer solutions,all over the world.

TRANSFORMER FINISH

With concealed wiring in rigidConduits, Junction Boxes ,Elbows etc. to the NECguidelines, a neat wiring layoutis offered. Great care is takenfor using thin, minimum widthjointless gaskets having minimalexposure and constrainedsealing system, to theinternational practices forabsolutely no leakage of the oil.

TRANSFORMER PACKING

While the main Tank istransported as per the planneddesign and logistics, theaccessories and tools, firstpacked in polyethylene, areshipped in standardisedseaworthy wooden packingboxes, with shipping marks andcontents specified for damagefree shipment.

TECHNICAL DOCUMENTATION

All the drawings are inAutoCAD, for quick review whilegetting approved and thereafterthe final drawings can besubmitted on a CD alongwith aprint copy as required.

The Transformer Installation,Commissioning andMaintenance Manual is in fullysearchable electronic format(PDF) on a CD for easy andquick access to the exhaustivetechnical instructions.

POWER TRANSFORMERS,EXPORTS ALL OVER THEWORLD!

Today over 400 units ofCrompton Greaves PowerTransformers up to 320 MVAand 345 kV are installed in over46 countries around the world.

Power Transformer shippingcalls for a specialised skillsetand meticulous planningthrough study of productspecifications, Port capabilitiesand shipping logistics to ensuresafe, reliable, timely and costeffective passage till installationsite in the destination country.Critical aspects of PowerTransformer logistics andshipment are planned and takencare of at the design stage itselfand the Crompton Greavesin-built expertise make asignificant contribution there.

The Result - Crompton GreavesPower Transformers, energisingsolutions for over 60 years now!

Product improvement is a continuous process. Hence datagiven in this catalogue is subject to change withoutintimation.

Transformer on trailer

Painting and finishing

The paint system, epoxy andacrylic based polyurethane,would be compatible to thespecified corrosive environmentwith good aesthetic finish.

9

Transformer Exports,Kanjurmarg (East),Mumbai (Bombay) - 400 042.(INDIA)Telephones : +91-22-578 2451Direct : +91-22-579 6902Fax : +91-22-578 0456Email : vk@cgl.co.inHome Page: http://www.cglonline.com/international/

CG.ID/PTransfo/54/3/02

.... for over 60 years!

EnergisingSolutions

CG InternationalInternational Operations ofCrompton Greaves Limited

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