SPECIAL PROCESS 155 The following operations in this process ensures absolutely leak proof welded jo ints: (a)

First, clean the joints by chipping-off the welding flux deposited during we lding. (b) Ensure that the fluorescent dye has covered the entire welded joint. (c) Allow a settling time of 20 to 30 minutes. (d) After cracks are identified by the ultraviolet ray, ensure that the rectific ation work is done successfully. In the case of sealed type tank with corrugated wall panel, leak tes ting by air pressure with soap-water is not recommended, since it destroys the flexibility of the corrugat ed panel. Such tanks should be checked for leakage either by hydraulic test or by fluoresc ent dye penetrating process as described above. Since it is a special process which affect the quality of the p roduct directly, it should preferably be done by skilled operators with pre-determined qualification criter ia. MS materials like sheets, angles, channels, pipes, radiators etc. are usually st ored in open yards, leading to rusting and pitting of their surface. It is difficult to remove the rust afte r the tank is fabricated with such materials. Since cleaning by emery paper is not sufficient, the tank should be cleaned by sand/shot blasting. To organize such cleaning, a closed de-humid chamber and a high power compressor is necessary. The tanks are placed up side down inside the chamber. Sand/shots are sprayed on the tank surface at a very high velocity, resulting in the removal of rust and welding scales. In this process, lightly pitted surface of the tank wall also gets cleaned leaving behind a bright smooth surfac e. For tank with medium rating transformer with moderately rusted and pitted surfaces, 20 to 30 minutes is essential to get it cleaned completely. The following points are to be taken care of to achieve satisfactory cleaning: (a) Select appropriate size of shots/mesh of sand (b) Choose adequate compressor air pressure to create the required speed of inje cting sand/shot (c) Ensure the quality of sand or shot for re-cycling (d) Fix the time for cleaning on the basis of the surface condition (e) After the cleaning operation, apply first coat of paint without much loss of time, definitely not later than 2 hours (f ) Ensure that only qualified workers are employed for this process. The process of brazing is almost the same as that of welding. In the case of wel ding two or more MS materials are joined together. Joining of two or more copper/brass materials is called brazing. Welding arc is developed by electricity, whereas, brazing is done by oxygen-ac etylene flame and a specially built electrode. Thin brass rod with approximately 14 per cent silver content is generally used as electrode for gas brazing. Commercial name of such an electrode is rupatem rod. In transformers with copper winding, taps of coils, delta and line leads, star p

oint, termination of leads on the bushing etc. are few examples where gas brazing is employed.156 POW ER TRANSFORMERS : QUALITY ASSURANCE Following are a few of the essential checks while carrying out gas brazing: (a) Surfaces which are to be brazed should be properly cleaned. (b) Select the right kind of electrodes with proper silver content. (c) Use right kind of torch for mixing oxygen and acetylene gases. (d) Considering the size of the objects to be brazed, control the oxy-acetylene flame. (e) Objects to be brazed should be red hot first before application of electrode s as filling material. (f ) After brazing operation, the job should be allowed to cool-down naturally. Movement of the brazed object under hot condition is not recommended. ( g) Use of wet cloth in the brazed joint, when hot, is to be avoided. (h) In case, the surface to be brazed is not properly cleaned, there is every po ssibility of a dry joint which may result in abnormal contact resistance. (i) Use of asbestos clay in the right location may protect the major insulation from burning. The operators should be sufficiently skilled. Appropriate job related t raining by way of demonstration by the expert, illustrative drawings etc. should be provided to th e operators. Active part of the transformer, i.e., core-coil assembly is de-moisturised in an electrically heated oven. Insulating materials like pressboard, paper etc. contain approximately 4 to 6 pe r cent water by weight. The water content in the insulating materials is even higher during monsoon. For example, a 5 MVA, 33/11 kV transformer has about 100 kg of paper insulation and pressboard and con tains approximately 6 kg of water particles. Water is very harmful as it deteriorates the di-electri c property of the insulating materials. It is therefore necessary to ensure that the water particles are comp letely dried out before adding oil to the transformer. Electrically heated oven is employed for such de-moisturisation process. The ove n is basically a steel chamber with a door at the front and fin type concealed heater s. Blowers and exhaust fans of adequate capacity are placed in suitable locations. Water particles turn into va pour due to heat and are taken away by the blowers and exhaust fans. Time and temperature are the two controlling parameters which are to be monitore d during the process. Operation of the heaters are controlled through thermostat so that the inside temperature of the oven does not rise beyond 80C. Control of time depends on the value of insulation resistance between windings and earth. The operation of the oven should continue till the insulatio n resistance attains its maximum value. Continuous monitoring during the entire operation of de-moisturising is very ess ential. Time vs Insulation resistance may be plotted on a linear graph sheet which wi ll give a fair idea of the time required to attain desired insulation resistance. Since the controlling factors

in the operation of the oven are temperature and insulation resistance, we must use calibrated temperature ga uges and megger to measure these parameters. Motorised megger is preferred to measure insulation re sistance. Qualified operators with adequate job knowledge only should be engaged for this operation.SPECIAL PROCESS 157 ! Filtration of oil is done to improve the breakdown value. It is done using a spe cial purpose machine, commonly known as stream line oil filter machine . Suspended foreign particles are removed through a strainer. Moisture is removed through heating and application of vacuum. The t emperature should remain between 60 to 70C. Temperature beyond 70C may deteriorate other properties of the oil. Temperature and vacuum are the two controlling parameters which are to be monito red during filtration. The operation should continue till its BDV attains the required valu e. Sub-standard oil or used oil should not be filtered through the machine, because when bad oil passes through the machine it leaves offensive foreign materials on th e filter disc, which will later adversely affect the quality of the good oil when it passes through the filter d isc. Periodic maintenance and change of filter disc after a pre-determined time is very essential. Qualified operators with adequate job knowledge only should handle this operatio n. " It is seen that some of the special manufacturing processes have direct effect o n the quality of transformer. These processes should be well defined in such a way that it is eas ily understood by the operators. Necessary description of the processes along with the work instructions should be displayed in the respective work places. In case, demonstration by way of illustrative photograph s, drawings, models etc. are necessary to explain the procedure, the same should also be done. It is essential to highlight certain points which have a direct impact on the qu ality. Example: (a) Set the current with respect to sheet thickness during arc welding (b) Control the operating temperature during oil filtration and operation of hea ting chamber (c) Set the required jet speed during sand/shot blasting (d) Set the appropriate air pressure during leak testing. The most important aspect in the operation of special processes is the function of the operators. Skilled workmen having sufficient job knowledge and working experience only shou ld be engaged to handle such processes. It is necessary to identify the qualification requirement s of the operators and then we need to ensure that only such workmen are engaged who satisfy the qualif ication criteria. These workmen are termed as qualified operators . A list of qualified operators should be readily available in the work premises. The outcome of such special processes should be closely monitored to ensure qual

ity output. Job related training by way of development of samples or through demonstration by th e experts are some of the methods of improving the skills of the operators.