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CPRI
HOW TO SAFE GUARD
THE TRANSFORMER..???
CONSISTENCY IN PERFORMANCE:
Good manufacturing practice
Adequate testing at all stages
Close monitoring to control process variable
Ideal case of process control : zero-defect
Any defect to be followed by root-cause analysis and
necessary system level changes to be introduced
CPRI
RELIABILITY IN SERVICE LIFE:
Ensured by adequate design margins and over-load
capacity
Maintenance instructions & steps to be taken in case of
break down, contingency plans and recovery procedures
to be provided
CUSTOMER SATISFACTION :
Ease of operation, maintenance free
Inter-changeability, rapid restoration of operation
Clear documentation, availability of spares
Speedy redressal of complaints
RAW COPPER
MATERIAL
IRON
SUPPLY- CORE
CHAIN INSULATION
DESIGN
COSTING
ACCESORIES
CRADLE-GRAVE
RISK POOL
COOLING
MAINTENANCE
&RLA
DISASTERS
R&R
PROCESS
QUALITY
CONTROL
Type Tests:
a) Lightning impulse test IS 2026 (Part 3).
b) Temperature-rise test IS 2026 (Part 2).
NOTE - Maximum measured total loss (No load at rated excitation + load
loss at maximum current tap converted to 75 C reference temperature) at
Special Tests:
a)Short-circuit withstand test IS 2026 (Part 5) (above 200
kVA)
NOTE Routine tests before and after short circuit test shall be conducted
as per IS 2026 (Part 1).
c) No load current at 112.5 percent voltage (see 5.9.3).
d) Paint adhesion tests. The test is performed as per ASTM
D3359 (Standard Test Methods for measuring adhesion by
Tape test).
a)Determination of sound levels IS 2026 (Part 10)
e) BDV and moisture content of oil in the transformer (IS
335).
NOTE Tests at d) and e) may be carried out on more than one unit subject
to agreement between user and supplier
Pressure test
Type test (for Routine test
30 minutes) ( for 10 minutes)
3, Non sealed 80 35
(Plain tank)
Corrugated tank 80 15
Sealed (upto 80 80
200kVA)
1, upto 25kVA) 100 35
Vacuum Test (Type Test)
COMPLETE TRANSFORMER
WINDING CPRI
Phenol resin
Insulation Paper Hard Paper Press Board paper tube
Mechanical tests Phenol resin
Mechanical tests Mechanical tests paper test
Electrical tests
Electrical tests Electrical tests Mechanical,
Machining test
Chemical tests Chemical tests Electrical tests
Punching tests
on tubes
Winding
Visual & Dimensional Control
Check for no. of turns
Inspection control after winding assembly &
winding finishing
Visual & Dimensional Control after winding
impregnation and pressing
CPRI
QUALITY CONTROL CHECKS
FOR TRANSFORMER
A. PAPER COVERED CONDUCTORS
(ALUMINIUM OR COPPER)
Assembly of core
Complete core Visual and Dimensional Control
High voltage test on core bolts
Watt loss
Stacking factor
Surface insulation
Visual and dimensional checks
CPRI
LAMINATION (PROCESSING)
CORE ASSEMBLY
Visual and dimensional checks
Verticality
Dielectric test on core bolt
Core loss test
ACTIVE PART ASSEMBLY
Core coil
CPRI
Lid complete assembly Active part Ratio Test
Visual & Transformers above
Visual &
Dimensional 500 kVA after
Dimensional Inspection Control
control Vaccum driving
control
High voltage test
FABRICATION
Visual and dimensional checks of tank
Pressure test
Dye penetration test on welded joints of tank
GASKET
Visual and dimensional check
D. OIL FILLING CPRI
Check for leakage in tank and at gaskets
Physical, chemical & electrical properties of oil
Volume resistivity
TRANSFORMER CPRI
Inspection control during /
Transformer after mounting of accessories
complete and devices
Routine tests
CUSTOMER
CPRI
F. TESTS ON ACCESSORIES