Transformer internship Report 2019

Change your life

INTERNSHIP REPORT

Department of Electrical Engineering,

The University of Faisalabad,
Faisalabad

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 INTERNSHIP REPORT
Submitted To:
HR
Submitted By:
Sharoon
Internship Department:
Transformer Reclamation Workshop

Department of Electrical Engineering,

The University of Faisalabad,
Faisalabad

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 TABLE OF CONTENTS

Dedication ………………………………………………………………………………4

Acknowledgement ………….………………………………………………………5

Exclusive Summary ……………………………………………………………….6

Transformer ……………….………………………………………………………….7

History of Transformer ……………………………………………………….…7

Uses of Power Transformer ……………………………………………………8

Parts of Transformer ………………………………………………………………8

Principle of Transformer …………………………………………………………14

Working of Transformer …………………………………………………………14

Manufacturing Department …………………………………………………….15

I&QC Department …………………………………………………………….…....30

Difference between Power and Distribution Transformer ……….38

Calculations …………….…………………………………………………………………38

Companies Name ……...………………………………………………………………39

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 Dedication

To all those who have supported, encouraged, challenged, and inspired me. And
specially to my Beloved Parents, honorable teachers and friends for all their
guidance, love & attention which has made it possible for me to make it up to this
point and as well as the Internship Supervisors who bestowed me with the
courage, the commitment and the awareness to follow the best possible route, by
their unmatchable style and by best possible training.

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 Acknowledgement
All the praises are for the almighty, Allah who bestowed me with the ability and
potential to complete this Internship. I also pay my gratitude to the Almighty for
enabling me to complete this Internship Report within due course of time.

Words are very few to express enormous humble obligations to my affectionate

Parents for their prayers and strong determination to enabling me to achieve this
job.

I take this opportunity to record my deep sense of gratitude and appreciation to my

teacher Mr. Murad Habib and Chairman Dr. Rafiq Ahmed, Department of
Electrical Engineering, University of the Punjab, Lahore for their constant
encouragement and inspiring guidance with their Wisdom.

I also appreciate the cordial co-operation from all my Internship Supervisors in

the different departments of PEL and also of HR management for providing me
requisite information and knowledge for compilation of my complete Internship.

All the employers of PEL helped me a lot in performing all the activities and in
gaining the practical knowledge of industry. They gave me best environment and
knowledge to enhance my skills.

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 Executive Summary
Pak Elektron Limited (PEL) is the pioneer manufacturer of electrical goods in
Pakistan. The company has always been contributing towards the advancement
and development of the engineering sector in Pakistan by introducing a range of
quality electrical equipment, home appliances and by producing hundreds of
engineers, skilled workers and technicians through its apprenticeship schemes and
training programs.

I recently have done my internship in PEL, in which I got training from its
Distribution Transformer unit. The internship basically revolved around the
transformer design, manufacturing, I&QC and maintenance. The system, the style
of working & the commitment of the employees in PEL is really exemplary.

The difference between the success & failure is doing things right and doing things
nearly right, & PEL has always tried for success & that is why it is known to be
one of the leading companies in Pakistan.

In this report I have given a very brief review of what I have seen and learnt
during my internship. I have mentioned all these as I have made an internship as
according to the schedule. This report will give its reader knowledge about the
PEL and power division especially about transformer unit.

I have made it possible to write each and every thing that I have learnt here. I have
all my practical efforts in the form of this manuscript that’s the asset for my future
career.

Definition:

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A transformer is a static machine used for transforming power from one circuit to another
without changing frequency. This is a very basic definition of transformer.

History of Transformer:
The history of transformer was commenced in the year 1880. In the year 1950, 400KV
electrical power transformer was introduced in high voltage electrical power system. In
the early 1970s, unit rating as large as 1100MVA was produced and 800KV and even
higher KV class transformers were manufactured in year of 1980.

Use of Power Transformer:

Generation of electrical power in low voltage level is very much cost effective. Hence
electrical power is generated in low voltage level. Theoretically, this low voltage level
power can be transmitted to the receiving end. But if the voltage level of a power is
increased, the current of the power is reduced which causes reduction in ohmic or I2R
losses in the system, reduction in cross sectional area of the conductor i.e. reduction in
capital cost of the system and it also improves the voltage regulation of the system.
Because of these, low level power must be stepped up for efficient electrical power
transmission. This is done by step transformer in the electrical power system. Two
winding transformers are generally used where ratio between high voltage and low
voltage is greater than 2. It is cost effective to use auto transformer where the ratio
between high voltage and low voltage is less than 2. Again, three phase single unit
transformer is more cost effective than a bank of three single phase transformer unit in a

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three-phase system. But still it is preferable to use than the later where power dealing is
very large since such large size of three phase single unit power transformer may not be
easily transported from manufacturer's place to work site. Up transformer at the sending
side of the power system network. As this high voltage power may not be distributed to
the consumers directly, this must be stepped down to the desired level at the receiving
end with the help of step-down transformer. These are the uses of electrical power

PARTS OF TRANSFORMER Basic Parts of a transformer:

The following are the basic components of a transformer.

I. Laminated core

II. Windings

III. Insulating Materials

IV. Transformer oil

V. Tap changer

VI. Conservator

VII. Breather

VIII. Cooling tubes

IX. Buchholz Relay

X. Explosion vent

Of the above mentioned, first four can be seen in almost all the transformers whereas the
rest can be found only in transformers more than 50KVA.?

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 CORE:
Core is used to support the windings in the transformer. It also provides a low reluctance path
to the flow of magnetic flux. It is made up of laminated soft iron core in order to reduce eddy
current loss and Hysteresis loss. The composition of a transformer core depends on such factors
as voltage, current, and frequency. Diameter of the transformer core is directly proportional to
copper loss and is inversely proportion to the iron loss. If diameter of the core is decreased, the
weight of the steel in the core is reduced which leads to less core loss of transformer and the
copper loss increase. The vice versa happen when the diameter is increased.

Winding:
There are two windings wound over the transformer core which are insulated from each
other. Windings consists of several turns of copper coils bundled together each bundle are
connected in series to form a winding. Windings can be classified in two different ways.
a) Based on the input and output supply b) Based on the voltage range Based on the
supply the windings are classified into a) Primary windings It is the winding to which the
input voltage is applied.

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 b) And secondary windings. It is the winding to which the output voltage is applied.
Based on the voltage the windings can be classified as follows a) High voltage winding
High voltage windings are made up of copper coil. The number of turns in it is the
multiple of the number of turns in the low voltage windings. It has copper coils thinner
than that of the low voltage windings. b) Low voltage windings Low voltage winding has
lesser number of turns than that of the high voltage windings. It is made up of the thick
copper conductors. This is because the current in the low voltage windings is higher than
that of high voltage windings. Transformer can be supplied from either LV or HV
windings based on the requirement.

Windings are made of copper due to the following reasons. • High conductivity 1.
Minimizes amount of copper needed for winding (volume & weight of winding) 2.
Minimizes losses • High ductility 1. Easy to bend conductors into tight winding around
core thus minimizes amount of copper and volume of winding? Insulating materials
Insulating papers and card boards are used in transformers of to isolate primary and
secondary winding from each other and from transformer core. Transformer oil is also a
insulating material.

Insulating Materials:

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 Transformer oil:
Transformer oil performs two important functions of insulation as well as cooling for the core
and coil assembly. Core and windings of the transformer must be completely immersed in the
oil. Normally hydrocarbon mineral oils are used as transformer oil. Oil contamination is a serious
problem because it robs its dielectric properties and renders it useless as an insulating medium.

Oil Name: Dichloro Difloro Methyl

Insulating oil in an electrical power transformer is commonly known as transformer oil. It is
normally obtained by fractional distillation and subsequent treatment of crude petroleum. That is
why this oil is also known as mineral insulating oil. Transformer oil serves mainly two purposes
one it is liquid insulation in electrical power transformer and two it dissipates heat of the
transformer i.e. acts as coolant.

Cooling system:

Conservator Tank:
Conservator conserves the transformer oil. It is an airtight metallic cylindrical drum
which is fitted above the transformer. The conservator tank is vented to the atmosphere at
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the top and the normal oil level is approximately in the middle of the conservator to allow
expansion and contraction of oil during the temperature variations. It is connected to the
main tank inside the transformer which is completely filled with transformer oil through a
pipeline.

Breather:
The insulating oil of transformer is provided for cooling and insulating purpose.
Expansion and contraction of oil during the temperature variations because pressure
change inside the conservator. This change in pressure is balanced by the flow of
atmospheric air into and out of the conservator. Transformer breather is a cylindrical
container which is filled with silica gel. Insulating oil reacts with moisture can affect the
paper insulation or may even lead to some internal faults. So, it is necessary that the air
entering the tank is moisture free. For this purpose, breather is used. Breather consists of
silica gel contained in a chamber. When the atmospheric air passes through the silica gel
breather the moisture contents are absorbed by the silica crystals. Silica gel breather is
acts like an air filter for the transformer and controls the moisture level inside a
transformer. It is connected to the end of breather pipe.

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 TAP CHANGER:
The output voltage may vary according to the input voltage and the load. During loaded
conditions the voltage on the output terminal fall and during off load conditions the
output voltage increases. In order to balance the voltage variations, tap changers are used.
Tap changers can be either on load tap changer or off load tap changer. In on load tap
changers, the tapping can be changed without isolating the transformer from the supply
and in off load tap changers it is done after disconnecting the transformer. Automatic tap
changers are also available.

Cooling tubes:
Cooling tubes are used to cool the transformer oil. The transformer oil is circulated
through the cooling tubes. The circulation of the oil may either be natural or forced
circulation. In natural circulation, when the temperature of the oil raises the hot oil
naturally moves to the top and the cold oil moves downwards. Thus, the oil keeps on
circulating through the tubes. In forced circulation, an external pump is used for
circulating the oil.

When transformer supplies a load, two types of losses occur inside the transformer. The
iron losses occur in the core while copper losses occur in the windings. The power lost
due to these losses appears in the form of heat. This heat increases the temperature of the
transformer

Buchholz Relay:
It is a protective device container housed over the connecting pipe from main tank to
conservator tank. It is used to sense the faults occurring inside the transformer. It is a
simple relay which is operated by the gases emitted due to the decomposition of

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transformer oil during internal faults. It helps in sensing and protecting the transformer
from internal faults. • How does a Buchholz relay work? Buchholz relay is a type of
protection relay universally used on all oil immersed transformers having rating more
than 500 KVA. From this article its principle and working can be understood.

Explosion vent:
Explosion vent is used to expel the boiling oil in the transformer during heavy internal
faults in order to avoid the explosion of the transformer. During heavy faults the oil
rushes out of the vent. The level of the explosion vent is normally maintained above the
level of the conservatory tank.

Principle:
A Transformer is basically is very simple static (or stationary) electromagnetic passive
electrical device that works on a principle of faraday's electromagnetic induction by
converting electrical energy from one value to another the transformer does this by
linking together two or more electrical circuits using common oscillating magnetic circuit
which is produced by the transformer itself. A transformer operates on the principle of
electromagnetic induction.

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Mutual induction is the process by which a coil of wire magnetically induces a voltage into
another coil located in close proximity to it. Then we say that transformers work in the
"magnetic domain" and transformers get their name from the fact that they transform one
voltage or one current level to another

WORKING:
Basic working of transformers: The basic transformer consists of two types of coils,
namely: 1. Primary coil 2. Secondary coil Primary coil the coil to which the supply is
given is called as the primary coil. Secondary coil the coil from which the supply is taken
is called as the secondary coil.

Based on the required output voltage the number if turns in the primary coil and the
secondary coil are varied. The processes occurring inside the transformer can be grouped
into two: 1. Magnetic flux is produced in a coil whenever there is a change in current
flowing through the coil. 2. Similarly change in magnetic flux linked with the coil
induces EMF in the coil. The first process occurs in the windings of the transformer.
When the ac supply is given to the primary winding alternating flux is produced in the
coil the second process occurs in the secondary winding of the transformer. The flux
alternating flux produced in the transformer links the coils in the secondary winding and
hence elf is induced in the secondary winding.

Manufacturing Department
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It is the responsibility of the manufacturing department to manufacture different
components of transformer and then assemble them to make a transformer. Production
department has following sections:

 Winding Section
 Core Section
 Tank Section
 Assembly Section

How manufacturing department starts manufacturing? First, customer gives order to the
marketing and sales department. Marketing and sales department makes annual sales
plan for WAPDA. Marketing and sales department sends this order to Production
planning and control department which makes a master production plan (Month wise).
This plan is sent to Material planning section which makes Material requirement plan or
Bill of material according to the master production plan. This plan is sent to the purchase
department which buys material according to this plan. Material is received in store
where quality inspectors from I&QC department check its quality than this material is
sent to manufacturing department where manufacturing of transformer starts.

Marketing and Production

Customer sales planning and
control

Annual Sales Plan No Sales Plan for Master Production

for WAPDA Private Plan(month wise)

Purchase Material planning

Store department section

Local Foreign Material Requirement

Plan or BOM

I &QC
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 Flow Chart of How Manufacturing Department

Production Planning and Control:

Production planning and control department receives order from marketing and sales
department. For WAPDA orders there is an annual sales report which is sent to the
production planning and control while for private orders are received from time to time
and there is no annual sales report for these orders. Production planning and control
makes the master production plan accordingly to the orders sent by marketing and sales
department. Master production plan is month wise and it can be changed. After making
the master production plan PPC makes a weekly production plan which is sent to
sectional in charges also makes the daily production plan. PPC apart from making the
master production plan and weekly production plan it monitors the production to ensure
that the production is running accordingly to the plan.

Material Planning Section:

Material planning section is responsible for the procurement of material and it ensures
that material arrives timely for the production. Material can be purchased from foreign
companies and also from the local companies. In local procurement material can be
purchased in less than a month so it is done once a month. In foreign procurement more
time is required because it takes more time for the arrival of material from foreign
countries by ships so foreign procurement is done after every three months. In foreign
procurement bank opens the letter of credit or LC, it pays the foreign company for the
material and the stock is pledged with the bank and when company needs the material for
production it pays the bank and material is given to the company for the production. After
the procurement of the material, material planning section follows the material to ensure
that it arrives on time for production.

1. Winding Section

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 In the winding section L.V and H.V windings of the coil are made.
 Raw Material
For L.V winding
 Paper insulated flat copper wire (For 10KVA to 50KVA)
 Copper foil (For 100KVA and above)

For H.V winding

 Enamel copper wire (For 10KVA to 200KVA)

 Paper insulated flat copper wire (400KVA and above)

 Type of Insulation Material

 Diamond dotted paper (For insulation between layers of windings)

 Press pan sheet (For end collars)

 Creep paper pipe (For insulation of terminal of tap changer)

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  Craft paper (Used for insulation in disc winding)

 Thermo ducts
 Types of Windings
 Disc winding
 Packet winding
 Layer winding
 Foil winding
File and layer winding are used in LV.File, packet and disc winding is used in
HV.Disc and packet winding are easy to repair.

 Machines Used

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  Slitting machine is used for the cutting of bundles of insulation material.

 L.V Foil winding machines are used for foil winding on L.V side for
transformers of the rating 100KVA and above.

 L.V paper insulated copper winders are used for winding of P.I copper
wire for transformers of the rating 10KVA to 50KVA.

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  H.V P.I copper winders are used for the winding of P.I copper wire for
transformers of the rating 400KVA and above.

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  H.V enamel copper winders are used for the winding of enamel copper
wire for the transformer of the rating 10KVA to 400KVA.

 Standard Ratings of WAPDA

Standard ratings of WAPDA are 10KVA, 15KVA, 25KVA, 50KVA, 100KVA,

200KVA, 400KVA, 630KVA

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 Supply of raw
materials

Paper slitting

L.V foil winding P.I winding (10

(100 &above) to 50)

H.V enamel Foil winding

(10k to 50k) (400 &above)

Storage area
for coils

Process Flow Chart of Winding Section

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HV winding is done over LV winding; both are insulated from each other. Connections
are made from start and end in LV and HV winding. But in HV we give taping
connection at different places according to design. On HV winding we used DDP paper
to insulate it from tank. Oil is also used for this purpose. Winding turns are according to
design. At the end of this section testing of winding is done using transformer turns ratio
(TTR) meter which gives no. of turns. we check it according to design.

2. Core Section

In the core section upper, side and yoke limbs of the core are made.

 Raw Material
Raw material used for the making of core is M4 grade silicone steel sheet which is an
alloy of iron and silicon. Silicon is used to increase the permeability of iron.
 Machines
 Slitting machine is used to cut the big roll of silicon steel sheet in required
sizes (widths) according to the rating of transformer.
 Power press machines are used to make limbs. They are operated manually.
 After cutting of limbs V punching is done on the yoke limb which is called
yoke notching.
 PLC cutting machines are also used to make limbs. There are two PLC
machines. SDRI machine has a capacity of 40,000 limbs per day. L.A.E
machine has a capacity of 60,000 limbs per day. In CNC machines length,
width and angle are given as input.
 L.A.E measuring table is used to check errors in angle, width and length.
 Iron Losses
Iron losses are the flux losses in core. Major factors in iron losses are;
 Quality of material.
 Bur.
 Air gap.

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To reduce iron losses

 Material should be of good quality.

 Limbs should be bur free.
 Limbs should be rust free.
 Weight of core should be according to Tr. Design

After cutting of the limbs, they are stacked in a way that there is no air gap between the
limbs. All the limbs are joined except the upper yoke limb which is filled in the assembly
section. Outer side of the core is varnished to avoid rusting. Core is tightened using upper
and lower pressing beams. Then it goes to assembly section.

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 Silicon sheet

Slitting of bundles

Cutting

Side limb Center limb Yoke limb

Core stacking

Varnishing of core

Checking of core

Stock

Process Flow Chart of Core Section

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3. Assembly Section (Major)
In the assembly section there are 17 processes in which all the components of the transformer
are put together to form a transformer. Important processes in the assembly section are;

 Core Coil Assembly

In the core coil assembly coil is fitted in the core and upper yoke limb is inserted to
complete the core, then core is tightened using upper and lower pressing beams. For coil
to coil insulation and core to coil insulation press pan sheet is used. For insulation
between bottoms pressing beam and coil wooden base is used.

 Before Connection Test (BCT)

In the BCT area turns ratio of the coil is checked using TTR meter.

 H.T, L.T Connections

In this section Y-Delta connections are made. Tap changer is connected with the coil.
Connections are made according to work order specifications given by the design
department. Taping is done on these connections to avoid any short circuit.

 After Connection Test (ACT)

In the ACT area turns ratio of the transformer is checked using TTR meter.

 Furnace (Oven)
After ACT transformer is kept in the furnace for 48 to 72 hours according to its rating. It
is done to evaporate all the moisture from core or coil. Temperature of the furnace is 120o
to 130o.

 Cover Plate Assembly

In this section H.T, L.T bushings, through bolts, eye bolts connectors, arcing horns and
other parts are inserted in cover plate.
 Pre-Tanking Section
When transformer is unloaded from the furnace it is inserted in the tank as quickly as
possible to avoid the getting of moisture in the live part. Live part of the transformer
should be inserted in the tank in 50mins to 1 ½ hours.
 Oil Filling Section
In oil filling section oil is filled in the tank under vacuum. Amount of oil to be filled can
be found from bill of quantity (BOQ). For 10kv to 200kv oil filling chambers are used and
for transformers above 200kv oil is filled manually.

 Settling Area

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 After oil filling every transformer is kept for 12 hours in the settling area to check for oil
leakage and oil level.

Supply of coils Core coil Supply of core and

upper yoke limbs
assembly

Before Connections
connections test

Furnace Assembly of After

cover plate connections test

Unloading Oil filling

Settling area

For testing

Process Flow Chart of Assembly Section

4. Tank Section
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 In the tanking section cover plate, tank, and other mechanical components of the
transformer are made. Tank has following parts;
 Frame
 Cover plate
 Bottom
 Side plate
 Fin Walls
 Conservator
 Raw Material
Raw material for tank and other components is
 MS sheet (Mild steel sheet)
 MSCR sheet (Mild steel cold rolled sheet)
 Shearing Machine
Shearing machine is used to cut the MS sheet in different sizes. This machine is used
for the cutting of frame, side wall, bottom wall and cover plate.

 CNC Nibbling and Punching Machine

CNC nibbling and punching machine has 32 tools to make holes of different size. It
can make
holes of the shape round, square, rectangle.

 Bending Machine
This machine is used to bend cover plate and frame.

 Embossing Machine
This machine is used for the embossing of holes on cover plate.

 Component Welding
In this area lifting lugs, carrying beams and studs are welded using arc welding.

 Frame Punching and Welding Machine

Frame is punched and then welded in this machine. MIG welding is used in this
machine.

 Fin Folding Machine

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 This machine is used for fin folding. Digital control panel is used to enter height,
weight and pitch. Pitch is the distance between two adjacent fins.

 Fin Welding
After fin folding, they are welded. MIG welding is used in this machine.

 Automatic Fin Welding Machine

MIG welding is used in this machine. Metal strip is welded to support the panel.

 Bottom Side Plate Welding

In this section bottom and side plates are welded together.

 Tank Assembly
Here all the parts of the tank are joint together.

 Tank Welding
Tank is welded to stop leakage.

 Shot Blasting
To remove oil particles from tank’s body and make its surface smooth shot blasting is
done. After that tank is dipped in degreasing, rinsing and phosphate tank to remove oil
particles.

 Sand Blasting
It is used for removal of oil particles from tanks make its surface smooth for
transformer rating above 200KVA.

 Tank Testing
For tanks up to 200KVA diesel spray testing is used. Above 200KVA pressure testing
is used to check leakage.

 Powder Coating
Tank is first passed through a chamber for pretreatment and then powder coating is
done.
Tank is painted with machines at end.

Inspection and Quality Control

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Inspection and quality control department ensures; material purchased by the purchase
department is according to the criteria suggested by IEC in their
recommendations(Incoming), during the manufacturing of transformers all the
components of transformer are according to transformer design(in processing),do all the
quality tests so that transformer does not fail in real conditions(Testing). Inspection and
quality control department is further divided into three sections

 Incoming
 In processing
 Testing
1. Incoming Section:
Incoming section is responsible for the checking of all the material which is purchased to
ensure that all the material is according to international standards. When the material is
purchased it first comes in the receiving where it is inward gate pass (IGP) number.
Incoming section checks through the system if material has arrived, then quality
inspectors from the incoming go to the store and check the material if material is
according to standards set by IEC than material is approved otherwise it is rejected and
supplier compliant application form (SCAF) is sent to supplier.

Material rejected SCAF generated

Purchase Receiving
Supplier department store

QUA INSPECTORS
(Incoming)

 Tests on Different Materials to Check their Quality

 Bird Protection Test

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 This test is used to check the thickness of paint so that cover plate will not short.
In this test 8kv voltage is applied to the cover plate for 1 minute if cover plate
does not stand it for, I minute than it is rejected.

 Micron Meter
Micron meter is also used to check the thickness of paint on cover plate. The
reading should be greater than .25mm according to IEC recommendations.

 Mandrill Test
This test is used to check the quality of enamel on enamel copper wire. For
mandrill test all sizes of enamel copper wire will be wound over its own diameter
for at least 8 to 10 turns and will be checked for zero cracks.

 Heat Shock Test

This test is used to check the quality of enamel on enamel copper wire. The
sample prepared for the mandrill test is placed in electric oven at temperature 155
Co to 166 Co for ½ hour and again mandrill test will be performed for test
compliance.
 Break Down Test
The specimen of wire approximately 600mm is doubled and twisted for a
distance of 125mm.The tension of wire pair while being twisted and a number of
twists will be as per specification (IEC-60317 and BS-4516).Enamel is removed
from the wire at one pair of ends and test voltage is applied between the
conductors through high port test set as per specification (IEC-60317). Note the
reading where break down has occurred.

 Peel Off Test

This test is applicable to sizes over 1.0mm. A sample of the wire of about 500mm
length is placed in tester consisting of two fixing devices 500mm apart on the
same axis. One of these is able to rotate. Specific weight is attached on the fix
side of device as mentioned in specification by IEC-60317. By means of a scraper
on opposite sides of wire.
The rotating device is driven at 60 to 100 revolutions per minute. The number of
revolutions of fixing device is calculated from R=175/d. After applying specified
number of revolutions chipping off of the enamel is checked. Zero chipping off is
required to qualify for enamel copper wire.

 Iron Loss Test

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 Iron losses of the silicon sheet (alloy of iron and silicon) are found using direct
reading iron loss tester. First diameter of the sheet is measured using
micrometer screw gauge. Diameter is fed in the iron loss tester. Tester is
energized for ½ hour and then iron losses are found. If 1.5 Tesla are applied in
tester than losses should not exceed .89 Tesla.

2. In Processing Section

In processing section ensures that during the manufacturing of transformers all the
components of transformers are according to design specifications. It is also
responsible for the testing of oil to check its quality.

 Oil Tests to Check its Quality

There are seven tests done in oil testing lab to check the quality of oil. If the oil
fails in one of these tests than it is rejected not used in transformers. Seven tests
are
I. Visual Inspection
II. Specific Gravity
III. Viscosity
IV. Flash Point
V. Dielectric Strength
VI. Acidity Value
VII. Pour Point

a) Visual Inspection
It should be free from contamination as per IEC-296 and IEC-60296
recommendations.

b) Viscosity
Viscosity meter is used for this test. Reading is taken at two different
temperatures. AT -20 Co reading should be less than 40mm2/sec and at 40 Co
reading should be less than 12mm 2/sec as per IEC-296 and IEC-60296
specifications.

c) Specific Gravity
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 Specific gravity meter is used for this test. Reading is taken at -30 C o. Before use
specific gravity of oil should be less than .895 g/mil. After use reading should be
less than .895 g/mil as per IEC-269 and IEC-60296 recommendations.

d) Flash Point
The point at which the oil catches fire is known as flash point. Flash point of
transformer oil should be greater than 140 Co as per new recommendation of IEC
in IEC-60296.

e) Dielectric Strength Test

Dielectric strength tester is used for this test. Oil is filled in a box which has
electrodes which are 2.5mm apart. Voltage is applied to the box which increases at
the rate of 2kv per sec. Reading is taken at point where breakdown has occurred.
Seven readings are taken and their arithmetic mean is the breakdown voltage. Oil
which is purchased should have dielectric strength greater than 30kv. When oil is
stored and all the moisture and impurities are removed than its strength should be
greater than 70kv. For the oil which is used reading should not be less than 55kv.
All these values are according to the recommendations of IEC mentioned in IEC-
60296.

f) Acidity Value
Acidity value meter is used for this test. For unused oil reading of meter should be
less than .03 mg KOH/g and for used oil it should not be less than .01 mg KOH/g.
Readings are according to recommendations of IEC given in IEC-60296.

g) Pour Point
The point at which oil freezes is known as pour point. Oil should not freeze before
-30 Co to pass this test.

Apart from checking the quality of oil, in processing section ensures that different
components of transformers which are manufactured according to transformer design and
are free from dimensional errors and other faults.

 In processing Inspection of Winding

 Diameter of the round side of L.V is measured to check if it is according to Tr.

Design.

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  Diameter of the straight side of L.V is measured to check if it is according to Tr.
Design.
 Diameter of the H.V is measured to check if it is according to Tr. Design.
 Overall diameter coil is measured to check if it is according to Tr. Design.
 Winding insulation is checked.

If any one of these things is not according to Tr. Design and out of tolerance limits
than it is rejected and fault card is issued.

 In processing Inspection of Core

 Cutting of the limbs is checked.

 Limbs should be smooth and bur free.

If these criteria are not met than that machine is closed for maintenance.

 In processing Inspection of Tank

 Pressure Test is used to check that there is no leakage in tank. In this test tank
is completely closed and pressure air is filled in the tank than a solution of
washing powder and water is dropped on every joint if there is leakage than
bubbles will be formed.
 Dimensions of tank are checked. They should be according to Tr. Design.

3. Testing
It is the responsibility of the testing section that the transformer does not fail in real
conditions. To check that it will not fail in real environment a number of tests are
done on the transformer before it is ready to dispatch. There are three types of tests
which are done on a transformer.
i. Routine Tests
ii. Type Tests
iii. Special Test

a) Routine Tests
Tests which are performed on each and every transformer are called routine tests.
Every transformer must pass these tests before dispatch.

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 b) Type Tests
Tests which are done on samples taken from a whole lot are called type tests.

c) Special Tests
Tests which are done occasionally on the requirement of customer are called
special tests.

d) Routine Tests:
There are eight routine tests done in testing section.

I. Transformer Turns Ratio Test (TTR Test)

II. Winding Resistance Test
III. Insulation Resistance Test (Meager Test)
IV. Induced Voltage Test
V. High Voltage Test (Separate source voltage)
VI. No Load Losses (Open circuit test)
VII. On Load Losses (Short circuit test)
VIII. Dielectric Tests

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1. Transformer Turn Ratio: (TTR Test)

Transformer turn ratio test is done twice on a transformer. Once before the connection
and once after the connection. Transformer turn ratio meter is used for this test. Turn
ratio should be as defined in Tr. Design to pass the test.
111 KVA
Requied turns= =46
√ 3∗239.5

2. Winding Resistance√

This test is used to check the phase to phase and phase to neutral resistance of
transformer. Phase to Phase resistance should be in ohms (Ω) and phase to neutral
resistance should be in milliohms (Ω).

3. Insulation Resistance Test: (Meager test)

This test is used to check insulation between

H.V Ground

L.V Ground

H.V L.V

4. Induced Over Voltage Test

This test is used to check the winding insulation. In this test voltage is applied on the L.V
side because it is easy to provide. On the L.V side twice the rated voltage at four times
the normal frequency is applied. Test time should be greater than 15 seconds and can be
found using the formula

Time = Rated frequency * 120

Test frequency

4. High Voltage Test: (Separate source voltage)

5. This test is used to check whether winding is insulated from other parts of transformer
or not. First, all the L.V terminals and body of transformer are earthed. Then 33kv
voltage is applied on the H.V side. IT is checked whether the transformer will stand
this voltage for 1 minute or not.

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6. No Load Losses: (Open circuit test)

In this test H.V side is kept open and voltage is applied on the L.V side. Then V, I, PF
and other quantities are measured.

7. Load Losses: (Short circuit test)

In this test L.V side is short and current is passed through the L.V side. Then V, I, PF and
other quantities are measured.

8. Dielectric Test

This test is done in the oil testing laboratory and break down voltage should be less than
mentioned in the IEC-60296.

Serial Difference between Power and Distribution Transformer

No.
1 33KVA (Above) 33KVA (Below)
132KVA,220KVA,440KVA 220,415,33KVA
2 Step Up & Step Down Always Step Down
3 Transmission & Receiving Distribution only
4 Load Fluctuation (High) Load Fluctuation (Low)
5 Fixed copper & iron losses Fixed Iron losses & Variable copper
losses
6 Operate at Full Load Operate at Low Load
7 Flux density (High) Flux density (Low)
8 Not used Tap Changer Used Tap Changer (Tapping)
9 Large Size Small Size
10 Very High Cost Low Cost
11 Star to Delta connection & Always Delta to Star connection
Delta to Delta connection

Calculations:

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To find Transformer H.V and L.V currents:
Rating∈KVA
Terminal Current=
√3∗Voltage
For Example: For 25KVA.
25 KVA
Primary Current = =1.3 A
√ 3∗11000
25 KVA
Secondary Current = =34.78 A
√ 3∗415

Serial No. Companies Name

1 PEL
2 SIMENS
3 Climax
4 Transpak
5 Til
6 Transfab

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