Power TransformersEnglish

Power Transformers

Power Transformers

Our Journey Towards Excellence

ISO 9001
ISO 14001
OSHAS 18001
CERTIFIED

Power Transformers

Expressions

of Power

Crompton Greaves Ltd., R & D operations are structured to
established in 1937, has witnessed initiate a techno-active response
over seven decades of unparalleled right through the company, getting
growth to have current sales of research out of the labs and in to
over INR 138.5 Billion (US $ 3 the products. Numerous awards and
Billion approx). With an electrifying ISO 9001, ISO 14001 and OSHAS
attitude, a fusion of experience 18001 certifications have accredited
and expertise in the field of applied its exacting standards of quality
energy, extensive R & D, advanced management.
technology, dedicated workforce, Today, Crompton Greaves
superior manufacturing skills, International Operations are
exacting standards of quality and spread over all the continents in
diverse and distinctive competencies the world to become among the
that converge, Crompton Greaves largest exporters from India in
offers a comprehensive portfolio each segment of Transformers,
of products and services for Switchgear and Controlgear, Motors
Generation, Transmission, and Alternators, Pumps and Fans.
Distribution and Utilization of power As the new millennium consumers
in various applications. Its presence plug-in to a switched-on future,
is well established and widespread, Crompton Greaves, a flagship
notably in the Utilities, Industry, company of Thapar led Avantha
Agriculture, Transportation, Group will continue to play an
Informatics, Telecommunication and electro-dynamic role …engineering
Lifestyle Products sector. the right solutions … making a
Crompton Greaves promotes a high difference to life and thriving in an
level of Research and Development increasingly wired world.
activities to maintain a technological
lead and competitive advantage.

CG House, Mumbai

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

Power Transformers

CG Group of Worldwide
Companies

Crompton Greaves Power Crompton Greaves Power Systems Transformer Plant, Belgium
System (Aquisition of Pauwels
Group, Belgium) key points, Pauwels continues to l Phase-Shifting Transformers
A Dream Accomplished operate as a “full-line supplier” (up to 500 MVA/525 kV)
Crompton Greaves had a long offering high performance and l HVDC Converter
cherished dream to become a proven reliability with maximum Transformers (up to
formidable Indian Multinational. return on investment for its 315 MVA/500 kV DC)
With the acquisition of the Belgium customers. l Reactors up to 500 kV
based Pauwels Group, CG has Pauwels’ full range of l Mobile and Compact
realized this most cherished dream. Transformers consists of: Substations (up to 500 MVA,
This acquisition will give CG l Liquid-filled Distribution 245 kV class)
Transformer manufacturing facilities Transformers for the distribution l Special Application
in 5 countries: Belgium, Ireland, of electricity to consumers Transformers which include
Canada, USA and Indonesia. CG is (15 kVA to 10 MVA/36 kV) Traction Transformers,
perhaps the only Indian Company l Cast Resin Transformers Testing Transformers and
to conclude an acquisition of (100 kVA to 10 MVA/36 kV) Slim Transformers
this complexity, magnitude and as an alternative to liquid-filled
geographical spread. distribution transformers, with
Crompton Greaves is now in the the emphasis on reduced
prestigious position of being environmental impact and
one of the top 10 Transformer increased fire safety
manufacturers in the world.
With the acquisition of Pauwels, CG l Medium and Large Power
will have access to Pauwels network Transformers (up to 575 MVA
of sales agents and customers 525 kV) for the transmission of
in over 135 countries. More than electrical energy
600,000 Pauwels’ Transformers
are currently in use throughout the l Auto-Transformers (up to Distribution Transformer Plant Missouri,
world. 700 MVA/525 kV) Washington, USA
Crompton Greaves Power
Systems
(Pauwels Transformers)
Since 1947, Pauwels group has
stood for innovative, high-quality
and reliable Transformers with due
respect to the environment and
service to customers around the
world. By creating a dynamic and
flexible company focused on these

Power Transformers

CG Power Holding NV CG Electric System Hungary Zrt. CG Service Systems France SAS
(Pauwels Contracting) (Ganz) (SONOMATRA)
Since its formation in 1977, Pauwels In 2008, Crompton Greaves completed
Contracting, (now CG Power Holding In mid - 2006, Crompton Greaves the aquition of Societe Nouvelle de
NV) has grown to become a significant have successfully completed another Maintenance Transformateurs SAS
division within CG. The company acquisition of two companies in (SONOMATRA) in France, a company
specializes in electrical turnkey projects Hungary i.e. Ganz Transelekro which specialises in providing
such as: Villamossagi Zrt. Engaged in the services of on-site maintenance/repair
l A.I.S. and G.I.S. substations business of EHV Trasformers, Gas of power transformers and on-load tap
up to 500 kV. Insulated Switchgear, Rotating changers, oil analysis, oil treatment
l Mobile substations and mobile Machines and Contracting and and retrofilling.
transformers up to 245 kV. an associate company of Ganz,
l Compact substations. Transverticum Kft engaged in the MSE Power Systems
supporting areas of design, erection, In 2008, Crompton Greaves acquired
commissioning and commercial the MSE Group based in USA, which
activity with high-end engineering and is engaged in Engineering, Procurement
substation capabilities. and Construction (EPC) of high voltage
electric power systems. It is specialised
CG Power Holding Ireland Limited in Conceptual Engineering, System
(Microsol) Studies, EPC Engineering, Spanning,
In 2007, Crompton Greaves acquired Relay/Control SCADA for Wind Parks,
the Microsol Group of Ireland, with Electrical Substations and Transmission
operations in Ireland, United States of Lines upto 500 kV
America and United Kingdom, with
expertise in the areas of sub-station
automation for MV and HV sub-stations,
with respect to both new sub-stations
and retro-fitting for existing
sub-stations.

Slim Transformers Distribution Transformers

Its core activities include electrical
projects for the wind energy industry.
The success of Pauwels Contracting
is also based on the energetic and
consistent application of a complete
range of professional project
management services.

Power Transformers

Smart solutions,
Strong relationships

... for over 70 years

Mumbai Plant Crompton Greaves kicked off the
Gwalior Plant Transformers operation with their
Bhopal Plant first supply to the US Army in 1937.
Bhopal Plant - Distribution Transformers Initial technology was from Brush
Transformers and Hawker Siddeley
Power Transformers, both from
U.K. and then, from Westinghouse
Electric Corporation, U.S.A. for
Transformers and Reactors upto
500 kV to match growing volumes
and changing international
requirements. Development
of 765 kV transformers was
completed successfully in technical
collaboration with Toshiba Japan.
2 units of 260 MVA, 765 kV
Generator transformers have
been manufactured, which were
supplied to NTPC, Sipat. Several
765 kV auto transformers are under
manufacturing for PGCIL. Having
commissioned over 200 Million kVA
in Transformers, Crompton Greaves
is today the leading manufacturer
of Transformers and Reactors,
with a wide range, for all critical
applications.
To sustain the growing demand of
Transformers, Crompton Greaves
commissioned a new integrated
plant at Gwalior (T2), spread over
20,000-sq. m. in 1991 and yet
another at Bhopal (T3), spread over
30,000-sq. m. in 1995. With the
acquisition of the Pauwels group
and Ganz, Crompton Greaves now
produces a staggerring 75,000
MVA of Transformers per annum in
10 plants across 3 continents. Of
this, the indian operations produce
over 30,000 MVA of Transformers
annually. This has enabled CG
to cater to the most demanding
markets of the world.

1

Power Transformers

Crompton Greaves have the Unitised Substation SPECIAL TRANSFORMERS
capability to produce transformers l Arc and Induction Furnace
from 5 kVA to 575,000 kVA (1.5 M DISTRIBUTION TRANSFORMERS Transformers Upto 60 MVA,
kVA in a bank), 3.3 kV to 765 kV l Oil Cooled Transformers, 38 kV.
class for various applications and 5 kVA to 10,000 kVA, 38 kV. l Trackside Transformers 31.5
conforming to IS, IEC, EN, AS, BS, l Dry Transformers, 100 kVA to MVA, 25 kV AC, single phase.
ANSI, CSA and other international 10,000 kVA, 36 kV l Locomotive Transformers upto
standards. l Unitised Substations. 7500 kVA, 25 kV AC.
l Thyristor Duty Transformers.
POWER TRANSFORMERS l Package Substations upto 2000
l Generator Transformers for kVA.
Thermal, Nuclear, Hydro and Gas l Earthing and Auxiliary
Generating Stations. Transformers.
l Upto 450 MVA, 500 kV class, l HVDC Convertor
three phase Transformers upto 300 MVA,
l Upto 810 MVA, 800 kV in a 500 kV DC
bank. l Mobile sub - stations upto
l 900 MVA, 500 kV in a bank 80MVA, 245 kV
l Auto Transformers for step-up
and step-down
l 500 MVA, 500 kV class, three
phase
l 1500 MVA, 800 kV in a bank.
l Reactors, Series and Shunt, upto
125 MVAr, 800 kV class.
l 1200 kV Auto Transformer under
development.

Oil Filled Distribution Transformer

Cast Resin Transformer

2

Power Transformers


LIST OF SHORT CIRCUIT TEST ON TRANSFORMERS

Description of Type Test Testing Type Test Customer for whom Year
Authority Report No. Test was made
Short Circuit Test
13.5/20 MVA, 132/27 kV Transformer CPRI, 87/STN-1/82 Railways, India 27.03.87
Short Circuit Test Bhopal
10/16 MVA, 132/11 kV Transformer
Short Circuit Test CPRI, 89/STN-1/272 PSEB,India 04.10.89
21.6 MVA, 132/27 kV Transformer - Sr. No. T8282/1 Bhopal
Short Circuit Test
10 MVA, 33/11 kV Transformer -Sr. No. T8369/1 CPRI, 90/STN-1/170 Railways, India 27.09.90
Short Circuit Test Bhopal 01.10.92
12.5 MVA, 66/11 kV Transformer -Sr. No - M2000/1 CPRI, 92/STN-1/212 MEW, UAE
Short Circuit Test Bhopal
20 MVA, 66/11 kV Transformer - Sr. No - T8551/3
Short Circuit Test CPRI, 96/STN-1/407 PSEB,India 30.11.96
21.6 MVA, 132/27 kV Transformer -Sr. No - T8704/1 Bhopal
Short Circuit Test
15 MVA, 66/11.55 kV Transformer -Sr. No - M2651/1 CPRI, 96/STN-1/411 PSEB,India 06.12.96
Short Circuit Test Bhopal
21.6 MVA, 220/27 kV Transformer -Sr. No. T8858/1
Short Circuit Test CPRI, HPL99163 Western Railway, 18.11.99
70 MVA, 220/6.9/6.9/6.9 kV Transformer Sr. No - T8847/1 Bangalore India
Short Circuit Test
25/31.5 MVA, 132/33 kV Transformer Sr. No - T8931/1 CPRI, 99/STN-1/316 GEB,India 08.12.99
Short Circuit Test Bhopal
21.6 MVA, 110/27 kV Transformer -Sr. No - T8947/1
Short Circuit Test CPRI, HPL02091 Railway Electrification 23.07.02
25 MVA, 400 kV Transformer Bangalore New Delhi, India
Short Circuit Test
32 MVA, 220 kV Transformer CPRI, HPL02147 NPC, India 30.11.02
Short Circuit Test Bangalore 06.10.03
102 MVA, 400 kV Transformer CPRI, 2003/STN-1/248 HPSEB, India
Short Circuit Test Bhopal
80 MVA, 400/11.5/11.5 kV Station Transformer
Short Circuit Test CPRI, 2003/STN-1/325 Central Railway, 09.12.03
315 MVA, 400 kV Transformer Bhopal Mumbai, India
Short Circuit Test
200 MVA, 400 kV Generator Transformer CPRI, HPL09050 URI, NHPC 2008
Bhopal

CPRI, HPL09051 CHAMERA, NHPC 2008
Bhopal

KEMA 159 - 08 SUBANSIRI, NHPC 2008
Netherlands

CPRI, HPL09130 NTPC 2009
India Simadri

KEMA 72 - 09 POWERGRID 2009
Netherlands

KEMA NTPC 2009
Netherlands

315 MVA, 440/220/133 kV
Auto Transformer at KEMA,
Netherlands

102 MVA, 400 kV Single Phase Generator
Transformer at KEMA Netherlands

3

Power Transformers

A DOMINANT PLAYER IN UHV 367 MVA, 750 kV Single Phase Auto Transformer,
SEGMENT Albertissa, Hungary.
Having supplied 750 kV transformers as
early as in 1977, CG Electric Systems
Hungary has been one of the early
manufacturers of 800 kV class
transformers. CG India has also become
a dominant player in 800 kV transformers
market in India. 260 MVA, 765 kV, Single
Phase Generator Transformer supplied
by CG India to NTPC was the first 765
kV transformer manufactured in India. At
present, several 765 kV transformers are
under manufacturing in CG India as well
as CG Hungary.
CG has also made a foray into 800 kV
class Shunt Reactors and 1200 kV class
transformers.
CG's UHV product range includes :
l 800 kV Class Generator Transformer
l 800 kV Class Auto Transformer
l 800 kV Class Shunt Reactors
l 1200 kV Class Auto Transformer
(Under development)

260 MVA, 765 kV Single Phase Generator Transformer supplied to NTPC Sipat
4

Power Transformers

3D View of Transformer components Transformers, Technology l ANSYS for seismic analysis.
Tank under simulation test for vacuum withstand Crompton Greaves have absorbed l ELECTRO for 2D Electrostatic
Layout of Dry Type Transformer world class technologies through
collaborations for built-in total Stress Analysis.
reliability. l ED MAG for Circulating current.
l ELDINST for Short Circuit
l Brush Transformers, U.K.
l Hawker Siddeley Power Behaviour current.
l Unigraphics and special add-on
Transformers, U.K.
l Westinghouse, U.S.A. for Foil software for components, parts
and their quick integration in to
Technology, Distribution and the final Product.
Power Transformers and Shunt l Simulation techniques for noise
Reactors upto 500 kV class. vibration, thermal, hot spot,
l GE, U.S.A. for Amorphous Core seismic analysis and short circuit.
Transformers
l ABB, Sweden for Locomotive Structural seismic analysis of Transformers
Transformers.
l Toshiba, Japan for 765 kV With deployment of well qualified
Generator and Auto Engineers and Technocrats,
Transformers Crompton Greaves have fully
l Pauwels Trafo, Belgium harnessed long experience in Design
l Ganz Hungary and Software, a core strength of
India, to offer innovative, reliable
Design technology incorporates the and efficient Transformer solutions.
following state of the art techniques Advanced computer systems,
and software to comply with the design techniques and simulation
ever demanding customer and of the field conditions contribute
system integration needs and the to fast product development and
latest manufacturing techniques. ensure enhanced reliability – so very
critical for the Transformers.
l 2D and 3D Finite Element
Method (FEM) analysis for
electrostatic and
electromagnetic distribution

l MAGNET for electromagnetics.
l VOLNA for Impulse Distribution
l IDEAS and ANSYS for

structural designs.

FEM analysis of core assembly

Clearance Sphere - design verification Transformer Engineering Centre at Mumbai Plant

5

Power Transformers

Power Transformers, Assembly Area Mandideep Plant, Bhopal
Core Building High Speed 'Georg' cnc Machine
Transformer Cores are built with
CRGO, low loss silicon steel lamina- 5-Limb Core assembly of 250MVA Generator Transformer
tions. Use of Hi-B grade and laser
scribed laminations for the core
significantly reduces no load losses
and noise levels as committed.
New high speed “GEORG” CNC ma-
chines for core slitting and cropping
offer stress free laminations without
burrs for fully aligned core build-
ing. Special dimpled sheets provide
space between laminations for most
effective cooling.
The laminations forming the mag-
netic circuit are assembled on a
special core building fixture. The
Step-Lap or Mitred joints at the
core corners ensure a streamlined
magnetic flux path.
The core limbs are held with resin
bonded glass bands to eliminate
limb bolts. Yokes are clamped by
solid mild steel plates with yoke
studs, ensuring high rigidity for
withstanding mechanical shocks
during transportation and short
circuits. For logistics, five limb core
construction offers reduced height
for large Power Transformers.

6

Power Transformers

Power Transformers, Micafil VPD Facility Power Transformers,
Winding Isostatic Press Core-Coil Assembly
Electrolytic Grade Copper or Epoxy Autoclave The winding is rigidly supported
Bonded Continuously Transposed by a common pressure ring of
Conductors (CTC) are used to the densified wood at the top and
design requirements. Windings are bottom, for precise alignment. Well
made on the vertical or horizontal profiled angled rings are placed
winding machines with great care by between HV and LV windings to
well-experienced techno-craftsmen reduce voltage stress levels. The
in a clean environment, (5 microns ends and tapping leads of all the
max.) with positive pressure for windings are connected by special
superior reliability. High quality pre- extra flexible, insulated copper
compressed insulation, pre shrunk cables, which are rigidly braced
by a specially designed process, in position. In oil forced units, oil
ensures long service stability. is circulated inside the winding by
Thermally upgraded paper enables specially designed pipes of insulated
emergency overloading beyond materials.
nameplate rating, wherever desired. The core coil assembly is dried to
The winding has axial and radial less than 0.5% moisture content,
cooling ducts to ensure effective by the automated Vapour Phase
heat dissipation in to the oil and Drying (VPD) plant of MICAFIL.
eliminating the hot spots. High mechanical rigidity is achieved
For high voltage windings, disc coils by hydraulic pressing at calculated
with excellent mechanical strength force and tightening all pressure
are used to take the stresses due to screws. The core-coil assembly
voltage level. A special interleaved is put into the tank with proper
or shielded construction offers most locating arrangements. The tank is
uniform voltage distribution despite then filled with hot oil, filtrated by
system transients. Finished coils High Vacuum Oil Filtration Plant
are compressed by predetermined to max. 5 PPM moisture content,
clamping force in a 200 tons, free of particles above 5 microns
Isostatic Hydraulic Press, for size and with very low gas content,
retaining the designed geometrical under vacuum to ensure least
position of the individual winding. exposure to atmosphere.

Winding Bay Mumbai Plant 7

Power Transformers

Power Transformers, Impulse Generator 2000 kVP, 200 Kilo-Joules 1. Switching and Lightning
Tanks from High Volt, Germany. Impulse Test System.
Tanks are built with mild steel 2. Partial Discharge and Radio
plates to withstand full vacuum, inspection of incoming materials, Interference Measurement
conforming to the International controlling in-process parameters Facilities.
standards. The welder’s qualification and thorough inspection and testing 3. Noise Level Measurement
is done as per ASME Section IX. of the Transformers ensure Setup.
Tanks are designed to roll and skid consistent high-quality standards 4. Temperature Rise Test Plant
in specified directions. that Customers have come to expect 5. Dissolved Gas Analyser
Lugs for jacking, lifting and from Crompton Greaves (DGA) for oil.
hauling are routinely tested for dye Test Facilities 6. Harmonic Measurement and
penetration. Tanks have welded In addition to the normal routine test Analysis
or bolted top cover. For large facilities, the following major type 7. Linearity Test Set for HV
units above 50 MVA, bell type test facilities are available in-house Reactors
construction is available. Tanks are for type testing the Transformers to 8. Vibration Test Plant
shot blasted to get a surface finish all major international standards. 9. SFRA Test
of SA 2.5, coated with zinc rich The Transformer designs are
primer and then painted. Epoxy or Test Bench proven for dead short circuits by
polyurethane painting and spray tests conducted at independent,
galvanising are optionally offered accredited Short Circuit
to specific requirements for surface Laboratories.
finish of the Tank. CGL has succesifully completed
The transformer is made ready for the short-circuit test on the
final inspection after assembly of following Transformers at KEMA,
bushings, conservator, radiators etc. Netherlands.
Power Transformers, 1 102 MVA, 16/400 kV, 1 phase
Quality Assurance generator transformer.
High standards set for procurement 2 315 MVA, 400/220/33 kV, 3
and inputs go a long way to ensure phase Auto transformer.
reliable Transformers. Quality is
ensured at source for standard Dissolved Gas Analyser for oil
materials, with a qualified and
dedicated Supplier base. Continuous
upgradation of Suppliers and close

8

Power Transformers

Process Certification Transformer Packing Power Transformers,
All the three manufacturing Plants While the main Tank is Exports all over the
are certified to ISO 9001-2000. transported as per the planned world!
Our Mumbai, Gwalior and Bhopal design and logistics, the Today over 600 units of Crompton
plants are additionally certified to accessories and tools, first packed Greaves Transformers up to 320
ISO 14001 standards by BVQI, in polyethylene, are shipped in MVA and 500 kV are installed in
U.K. Mumbai and Bhopal plants are standardised seaworthy wooden over 75 countries around the world.
also certified for OHSAS: 18000 packing boxes, with shipping marks Power Transformer shipping
A structured TQM programme and contents specified for damage calls for a specialised skillset and
is in place ensuring continuous free shipment. meticulous planning through study
improvement towards world class Technical Documentation of product specifications, Port
quality standards. The quality All the drawings are in CAD, for capabilities and shipping logistics to
assurance systems are backed by a quick review while getting approved ensure safe, reliable, timely and cost
strong in-house R & D continuously and thereafter the final drawings can effective passage till installation site
working to upgrade and ensure total be submitted on a CD alongwith a in the destination country. Critical
system reliability. print copy as required. aspects of Power Transformer
With SAP/R4 and PLM The Transformer Installation, logistics and shipment are planned
implementation, the internal Commissioning and Maintenance and taken care of at the design stage
processes are further sharpened Manual is in fully searchable itself and the Crompton Greaves
to provide effective Transformer electronic format (PDF) on a CD in-built expertise make a significant
solutions, all over the world. for easy and quick access to the contribution there.
Transformer Finish exhaustive technical instructions.
With concealed wiring in rigid
Conduits, Junction Boxes , Elbows
etc. to the NEC guidelines, a neat
wiring layout is offered. Great care
is taken for using thin, minimum
width jointless gaskets having
minimal exposure and constrained
sealing system, to the international
practices for absolutely no leakage
of the oil.

Painting and finishing 3 x 250, 550/275/33 kV, Single Phase Auto Transformer, Kapar Substation, TNB Malaysia

The paint system, epoxy and acrylic
based polyurethane, are compatible to
the specified corrosive environment and
have a good aesthetic finish.

Product improvement is a continuous process. Hence data given in this catalogue is subject to change without intimation. 9

Power Transformers

Smart solutions,
Strong relationships

... for over 70 years

Loading on Ship

Crompton Greaves Limited Transformer Exports, Transformer Domestic, CG.ID/PTransfo/RPT/54/01/10
Kanjurmarg (East), Kanjurmarg (East),
Mumbai - 400 042.(INDIA) Mumbai - 400 042.(INDIA)
Telephones : +91-22-2579 6902 Telephones : +91-22-6755 8000
Direct : +91-22-6755 8368 Direct : +91-22-6755 8372
Fax : +91-22-2578 0456 Fax : +91-22-2578 3271
Email : [email protected] Email : [email protected]

Registered Office :
CG House, 6th Floor, Dr. Annie Besant Road, Worli, Mumbai 400 030, India
W: www.cgglobal.com