Internship

On
Distribution Transformer
An internship submitted in partial fulfillment of the requirements for the
Award of Degree of
Bachelor of Science in Electrical and Electronic Engineering
At
Bachar Engineering Limited

By

Student Name: Student Id:

Md. Sazzadul Islam 171030007
Md. Zahidul Islam 171030008
Mithun mitra 171030012

Supervised by
MD:MIZANUR RAHAMAN
Lecturer & Program coordinator (Eve), EEE

DEPARTMENT of ELECTRICAL AND ELECTRONIC ENGINEERING

FACULTY OF SCIENCE AND ENGINEERING
GREEN UNIVERSITY OF BANGLADESH
July, 2020

Green University of Bangladesh Page 1

 CERTIFICATION

This is to certify that this internship entitled distribution transformer at basic power
engineering limited in partial fulfillment of the requirements for the degree of Bachelor of
Science in Electrical and Electronic Engineering. The presentation of the work was held on 17
December, 2019.

Signature of the Candidates

Md. Sazzadul Islam

ID: 171030007

Md. Jahidul Islam

ID: 171030008

Mithun Mitra
ID: 171030012

MD:MIZANUR RAHAMAN
Supervis
Lecturer & Program coordinator (Eve)
Department of Electrical and Electronic Engineering.
Faculty of Science and Engineering
Green University of Bangladesh, Dhaka

Green University of Bangladesh Page 2

The internship entitled “Distribution Transformer” submitted by Md.Sazzadul Islam, ID:
171030007, Md. Zahidul Islam, ID: 171030008 and Mithun Mitra, ID:171030012 ,Session:
Summer 2020 – Fall 2020 has been accepted as satisfactory in partial fulfillment of the
requirements for the degree of Bachelor of Science in Electrical and Electronic Engineering on 25
July, 2020

BOARD OF EXAMINERS

Dr. Md. Fayzur Rahman Chairman

Professor and Chairperson
Department of EEE, GUB

MD:MIZANUR RAHAMAN Supervisor

Lecturer & Program coordinator (Eve)
Department of EEE, GUB

Engr. Ahmed Al Mansur Internal Member

Asst. Professor
Department of EEE, GUB

Engr. Hasan Maruf

Asst. Professor Internal Member
Department of EEE, GUB

Green University of Bangladesh Page 3

 Dedicated
To
Our Parents

Green University of Bangladesh Page 4

 Table of Content
Contents Page No.

I Acknowledgement ---------------------------------------------------------------------------------07

II Executive Summary --------------------------------------------------------------------------------08

1. Chapter 1 ---------------------------------------------------------------------------------------------09
1.1 Introduction --------------------------------------------------------------------------------------09
1.2 Background ---------------------------------------------------------------------------------------09

1.3 Objectives of Our Internship --------------------------------------------------------------------10

1.4 Methodology -------------------------------------------------------------------------------------- 10

1.5 Limitations ------------------------------------------------------------------------------------- 11

1.6 Internship Report Outline ----------------------------------------------------------------- -------- 11

2. Chapter 2 ----------------------------------------------------------------------------------------------12

2.1 Background of Basic power Engineering Ltd. (BPEL) -----------------------------------------12

2.2 Mission ------------------------------------------------------------------------------------------------12
2.3 Quality and Environment Policy -------------------------------------------------------------------13
2.4 Scope ---------------------------------------------------------------------------------------------------13
2.5 Achievements and Awards --------------------------------------------------------------------------13

3. Chapter 3 -----------------------------------------------------------------------------------------------14

3.1 Definition of Transformer -------------------------------------------------------------------------- 14

3.2 Uses of Transformer ----------------------------------------------------------------------------------14

3.3 Basic Constriction and Working Principle of Transformer -------------------------------------15

3.4 Efficiency of A Transformer ------------------------------------------------------------------------16

3.5 Classifications of Transformer ----------------------------------------------------------------------17

4. Chapter 4 -----------------------------------------------------------------------------------------------18

4.1 Distribution Transformer ----------------------------------------------------------------------------18

4.2 Technical Specification of 400kVA, 11000/415V 3-∅Distribution Transformer -----------19

4.3 Different Parts of Distribution Transformer ------------------------------------------------------20

4.4 Transformer Losses ----------------------------------------------------------------------------------29
5. Chapter 5 ----------------------------------------------------------------------------------------------33

5.1 Basic Calculation ------------------------------------------------------------------------------------33

5.2 Cutting Core ------------------------------------------------------------------------------------------42

5.3 Core Assembling -------------------------------------------------------------------------------------43

5.4 Coil Windings ----------------------------------------------------------------------------------------45

5.5 Core Coil Assembling ---------------------------------------------------------------------------------46

5.6 Tap Changing ------------------------------------------------------------------------------------------47

5.7 Heat Chamber ------------------------------------------------------------------------------------------48

6. Chapter 6 ------------------------------------------------------------------------------------------------50

6.1 Oil Test -------------------------------------------------------------------------------------------------50

6.2 Measurement of Voltage Ratio ----------------------------------------------------------------------51

6.3 Resistances Test ---------------------------------------------------------------------------------------52

6.4 Megger Test --------------------------------------------------------------------------------------------52

6.5 High Voltage Test -------------------------------------------------------------------------------------53

7. Chapter 7 ------------------------------------------------------------------------------------------------54

7.1 Conclusion ---------------------------------------------------------------------------------------------54

7.2 Recommendation ----------------------------------------------------------------------------------- 55

References ----------------------------------------------------------------------------------------------56
 Acknowledgement
The successful completion of this report is the outcome of the contribution of a number of people
to whom we are grateful and thank them from the very deep of my heart. So, we would like to
take this opportunity to thank all those people who helped me in preparing this practicum report.
At the very beginning we would like express my deepest gratitude to Allah for giving me the
strength and the composure to finish the task within the schedule time.
Then, we would convey my special thanks to my parents whose inspirations have enabled me to
complete this report of this particular course.

Then, we would like to express my warm gratitude and cordial thanks to my supervisor
MD:MIZANUR RAHAMAN, Faculty of Green University of Bangladesh (GUB) Faculty of
whose guidance & help was very much required to prepare the report successfully.

we like to give special thanks to Basic Power Engineering Limited to give me an opportunity to
do internship in this reputed Company. We are very grateful to my co-supervisor Engr. Md.
Amir Uddin (Technical), for giving his valuable time & guidelines about my report. we thank
all the employees for being friendly and cooperative. we would taught lots of important things
through-out my internship career because of their proper attention and co-operation. we would
like to express deepest appreciation to Engr. Md.Anisuzzaman Manik, Engr. Ariful Haque for
their humble co-operation for the completion of the report.

Finally, we would like to thank honorable Chairperson, department of EEE, Prof. Dr. Md.
Fayzur Rahman because he designated such an environment for learning through which we got
the opportunity to acquire knowledge under B.sc EEE program, and that will be very helpful for
my prospective career.
 Executive Summary
Bachar Engineering Ltd. is the pioneer manufacturer of transformers and electrical goods in
Bangladesh. The company has always been contributing towards the advancement and
development of engineering sector in Bangladesh by introducing a range of quality of
distribution transformers with different ranges & other electrical equipment’s like – Switchgear
equipment, distribution board etc. we recently have done my internship in Basic power
Engineering Ltd. In which I got training from its transformer section. The internship is basically
on manufacturing, assembling, and testing process of distribution transformer.

The starting of this report with some fundamental data about introduction, background,
objectives, methodology and limitations are shown. Then we have discussed about distribution
transformers, its working procedure, its classifications based on its applicability, its efficiency
etc. The report includes manufacturing process step by step with core cutting, HT, LT winding,
assembling core and coil, tanking up, bushing, oil filling etc. we have tried to describe the whole
calculation process of the rated transformer with its testing procedure along with test reports
which was observed by me.

In this report, we have given a very brief review of what we saw and learnt during in our
internship period. We have mentioned all those things which we have learnt in our internship
period. This report will give its reader the knowledge about the Bachar Engineering Ltd. and
distribution transformer. We tried our level best to make the report simple but informative.
 Chapter 01: Introduction
1.1 Introduction
The purpose of a distribution transformer is to reduce the primary voltage of the electric
distribution system to the utilization voltage serving the customer. A distribution transformer is a
static device constructed with two or more windings used to transfer alternating-current electric
power by electromagnetic induction from one circuit to another at the same frequency but with
different values of voltage and current.

The construction of a transformer comprises two active components: the ferromagnetic core and
the windings. Within the transformer industry, the core and windings together are normally
referred to as the “active part”. The passive part of a transformer is the cooling system, in case of
liquid-immersed transformers consisting of the tank and the cooling liquid (mineral oil, silicone
fluid etc).

1.2 Background
As a partial fulfillment of the B.Sc. in EEE program I have done this practicum report on titled
“Manufacturing, Assembling, & Testing Process of 400kVA 11000/415 V, 3-Phase Distribution
Transformer” at “Bachar Engineering Limited ” under the instruction of Engr. Amir Uddin(Technical),
Engr. Md.Anisuzzaman Mank, Engr. Ariful Haque (Transformer Section).

Bachar Engineering Limited is one of the well know industry in assembling transformers and Electrical
Products. Basic Power Engineering Limited offers customers complete substation equipment and
transformers. Their main products are transformer, HT Switchgear, LT Switchgear, SDB board, DB
Board, PFI Plants, Motor Controlling etc. Since 2007, Bachar Engineering Limited has already become
best choice for its products and service to the customers countrywide.
Bachar Engineering Ltd transformer manufacturing has some characteristics as given as below:-
1) Bachar Engineering Ltd ensures guarantees of product by following code and
conducts of ISO 9001:2008.

2) Ensures security against physical harms.

1.3 Objectives

Broad Objective:

The broad objective of this report is mainly to understand the manufacturing, assembling, and
testing process of distribution transformer and applying this knowledge for improving the ability
& increasing the capability of the power sector of our country.

Specific objectives
In order to obtain the broad objectives, I have to find out the following objectives. They are
follows:
To gather practical knowledge about working process of transformer.
To know the manufacturing procedure of transformer.
To know the calculation process of a transformer.
To know the assembling process of transformer.
To know the testing procedure of transformer.

1.4 Methodology
The project is concentrated of the Manufacturing, Assembling, and testing of Distribution
Transformer. Both primary and secondary data are being collected for the purpose of this report.

Primary data: Primary Data are collected from the practical work, maintenance chart and
the user manual handbooks.

Secondary data: Secondary data was collected from the online internet resources, books,
journals.

1.5 Limitations:
Though I have completed my report within my practicum period but three months are not
enough to learn all the things that are available in Bachar Engineering Limited. I faced some
problems which eventually became the limitations of my project,
They has less Engineers and Technicians for this reason they always remain busy with their
own work so it takes more time to me gather all the information from them. Even they have
not enough first aid facility. In case of any kind of accident the medical treatment won’t be
found immediately as the area is far away from qualified hospital. They have no fixed
calculation manual for transformers so, I got some problems for collecting this calculation
from engineers of transformer section.

1.6 Internship report outline

Chapter-1 is the introductory chapter which gives a general idea about a Bachar Engineering
Limited (BPEL) and methodology of our Internship
Chapter-2 Describes the Background of Bachar Engineering Ltd. (BEL) and Mission
Chapter-3 Describe on the Classifications of Transformer and Basic Constriction and Working
Principle of Transformer
Chapter-4 Shows the Different Parts of Distribution Transformer and Transformer Losses
Chapter-5 Basic Calculation of Distribution transformer and Core Coil Assembling
Chapter-6 Describe on the Testing of transformer
Chapter-7 Recommendation and Conclusion
 Chapter 02: Organizational Overview
2.1 Background

The Bachar Engineering Ltd, an organization in private sector was incorporated in 2003
under the leadership of qualified young and dynamic partners to fulfill the domestic
electrical requirements of almost every new organization of the country. Bachar
Engineering Ltd. is now the largest transformer and switchgear manufacturing company
in Bangladesh. The company has wide variety of Distribution Transformers, HT-High
Tension Switchgear, LT-Low Tension Switchgear, PFI- Power Factor Improvement
Panel, DB- Distribution Board etc. All these products are incompliance with
internationally recognized standards,

Including,

ANSI: American National Standards Institute

NEMA: National Electrical Manufacturing Association
VDE: Regulation and DIN standard
ASTM: American Society of Testing Materials
IEC: International Electro-technical Commission
IEEE: Institute of Electrical and Electronics Engineering

The company gives utmost importance to customer satisfaction in all respect is now
looking forward to global recognition by adopting internationally recognized quality
system.
2.2 Mission:
We are committed to maintain our leading role in Power Sector; Power Transmission &
Distribution with the help of our skilled & professional staff members in order to execute
the challenging projects in timely manner with customer focused policy. The company
aims to achieve this mission not only through best quality products but also through excellence
in its service [6].

2.3 Quality and Environmental Policy:

Bachar Engineering Ltd. Trust that the foundation of a successful quality and environmental
management system will enable our organization to accomplish its vision of turning into a much
regarded fabricator and make of different inner and outside electrification items products. The
organization is firmly resolved to lead in this industry by giving fulfillment to our clients and
consenting to all related ecological laws and different necessities that we subscribe to [9].

2.4 Scope
This report has been prepared through the assistance of the help of practical knowledge and
broad discussion of my selected supervisor, technical engineer and employees of this
organization. While Preparing this report, I had a great opportunity to have an in depth
knowledge of Manufacturing and Testing procedure of Distribution Transformer. This Practical
Knowledge will help me to apply my knowledge to related field.

2.5 Achievements and Awards:

Since its inception in 2003, Bachar Engineering Ltd. has through its dedication and service,
achieved distinction as the Leading Power Engineering Company in Bangladesh. They have
earned the respect and trust of globally renowned companies. We are also in the process of
getting certified by ISO 14000 and ISO 18000. Throughout the journey till this point they have
achieved both materialistic and abstractive recognition, certification, award and records that have
only inspired them to achiever even bigger [9].

Chapter 03: Overview of Transformer

3.1 Definition of Transformer
Transformer is a static device which transforms electrical energy from one circuit to
another without any direct electrical connection and with the help of mutual inductance
between two windings. It transforms power from one circuit to another without changing
its frequency but in different voltage level. A varying current in the first or primary
winding creates a varying magnetic flux in the transformer's core and thus a varying
magnetic field through the secondary winding. This varying magnetic c field induces a
varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is
called inductive coupling.
If a load is connected to the secondary, current will flow in the secondary winding, and
electrical energy will be transferred from the primary circuit through the transformer to
the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in
proportion to the primary voltage (Vp) and is given by the ratio of the n umber of turns in
the secondary (Ns) to the number of turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus enables an alternating

current (AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down"

by making Ns less than Np [5].

3.2 Uses of Transformer

Electricity is very important in our lives; we cannot imagine a day without it. At present
day, the technology is rapidly growing, so, we use a number of appliances in our day to
day activities that are too precious to us. For this we need uninterrupted electricity to
make them work. To make sure uninterrupted electricity we use Transformer. Because
energy is lost in the process of long distance transmitting system of electricity , such as
during the journey from a power plant to our home. Less energy is lost if the voltage is
very high, so electrical utilities use high voltage in long-distance. However, this high
voltage is too dangerous for home use. Electrical utilities use transformers to change the
voltage of electricity as it travels from the power plant to us. First, the voltage of
electricity coming from the power plant is "stepped up" using transformers to the right
level for long-distance transmission. Later, the voltage is stepped down before it enters
our home - once again using transformers.

3.3 Basic Construction and Working Principle of Transformer

The physical basis of a transformer is mutual inductance between two circuits linked by
common magnetic flux through a path of low reluctance. An elementary transformer
consists of a soft iron or silicon steel core and two windings, placed on it. The windings
are insulated from both the core and each other. The core is built up of thin soft iron or
low reluctance to the magnetic flux. The winding connected to the magnetic flux. The
winding connected to the supply main is called the primary and the winding connected to
the load circuit is called the secondary. When the primary winding is connected to an ac
supply, current flows through it. Since this winding links with an iron core, so current
flowing through this winding produces an alternating flux in the core. Since this flux is
alternating and links with the secondary winding also, so induces an emf in the secondary
winding. The frequency of induced emf in secondary winding is the same as that of the
flux or that of the s supply voltage. The induced emf in the secondary winding enables it
to deliver current to an external load connected across it. Thus the energy is transformed
from primary winding to the secondary winding by means of electro-magnetic induction
without any change in frequency. The flux Ø of the iron core links not only with the
secondary winding but also with the primary winding, so produces self-induced emf in
the primary winding: This induced in the primary winding opposes the applied voltage
and therefore sometimes it is known as back emf of the primary.
The primary is the winding, which receives electric power, and the secondary is the one
which may deliver it. The coils are wound on a laminated core of magnetic material. The
two coils possess high mutual inductance. If one coil is connected to a source of
alternating voltage, an alternating flux is set up in the laminated core, most of which is
linked up with the other coil in which it produces mutually induced emf (electromotive
force) according to the Faraday’s laws electromagnetic induction i.e.

Figure 3.1: Transformer working principles [7].

di
EM
dt

Where,

e =induced emf

M = mutual inductance

If the second circuit is closed, a current flow in it and so electric energy is transferred
from the first coil to the second coil.

In Brief, a transformer is a device that,

Transfers electric power from one circuit to another

Transfer electric power without any change of frequency
It accomplishes this by electromagnetic induction and
The two electric circuits are in mutual inductive influence of each other [1].

3.4 Efficiency of a Transformer

An ideal transformer would have no losses, and would therefore be 100% efficient. In
practice energy is dissipated due both to the” copper losses” and “iron losses” but these
losses are very little. Transformers are in general highly efficient, and large power
transformer have efficiency to 99.75% as high. Small transformers such as a plug-in used
to power small consumer electronics may be less than 85% efficient.

3.5 Classifications of Transformer

Transformers are used in every power plant, all grid substations, buildings, in the
industry, the underground installations, wind turbines, on platforms, marine vessels,
under the sea, etc. Due to peculiarities of all these applications, many different types of
transformers have been developed in the course of history. To simplify the overview of
many transformer types, it is useful to have some kind of systematic classification. But
this is not easy to do because there are many ways of doing it. The transformer types
could be classified according to their power ratings, size of the windings, voltage,
current, weight of the transformers, type of cooling etc., but such approach would have a
limited applicability. The applications of each of the following types of transformers:

Power Transformer
Distribution Transformer
Auto transformer
Isolation transformer
Instrument transformer
Reactor transformer
Furnace transformer
Rectifier transformer

Distribution Transformers:

We are discuss only distribution transformer .They are used in the distribution networks
in order to transmit energy from the medium voltage (MV) network to the low voltage
(LV) network of the consumers. Their power is usually ranging from 50 to 1600 kVA.
Ampere rating is increased in a distribution transformer by increasing the size of the
primary and secondary windings; voltage ratings are increased by increasing the voltage
rating of the insulation used in making the transformer.
 Chapter 04: General Concept of Distribution Transformer

4.1 Distribution Transformer

A distribution transformer is a transformer that provides the final voltage transformation
in the electric power distribution system, stepping down the voltage used in the
distribution lines to the level used by the customer. Many industry standards tend to limit
definition by kVA rating. Distribution transformers can have lower rating and can have
5kVA to 10MVA [2].

Figure 4.1: Distribution Transformer

4.2 Technical Specification of 400kVA, 11000/415V 3-∅Distribution
Transformer

Table 4.1: Rating of transformer

Brand Bachar Engineering Ltd.
Type of transformer Step down
Serial No 400-00
Rated power 400 KVA
Rated voltage HV side – 11 KV LV side – 415 V
Rated current HV side –20.99 A LV side –556.48
A
Phase 3
Rated Frequency 50 Hz
Vector Group Dyn11
Connection type HT side – LT side – Y
Cooling type ONAN
Insulation Level

Impulse (Peak) HV Side- 75KV

Power Frequency HV Side -28 KV LV Side -3 KV

Temperature Rise
In Oil 60°C
In Windings 65°C
No Load Loss 788W
Load Loss 4869.13W
Impedance voltage 4%
Total Weight 1450 Kg.
Oil Quantity Ltr. 390
MFG Year 2017
4.3 Different Parts of Distribution Transformer:
Transformer’s Parts are shown
Core
Copper wire for (HT and LT side)
Insulation paper
HT bushing
LT bushing
Tap Changer
Channel
Separator
Transformer Tank
Radiator
Transformer Oil
Oil Level Indicator
Conservator Tank
Breather
Temperature Meter
Horn Gap
Buchholz Relay
Core:
As like as other electronic devices, transformer are included a huge number of parts, each
conjunction with the others to guarantee the safe and effective transmission of vitality.
The core makes up the bulk of a transformer, so it's nothing unexpected that choosing the
correct material assumes a basic part in the transformer's general capacity. There are
many types of cores are available such as s steel laminated, solid, and air core, as well as
variations of each within their respective categories.
 Figure 4.2: Core

Copper Wire for HT and LT Side:

Copper and aluminum are the only two winding material used in transformer there are no
other winding material that are able to be used as efficiently and economically.

Figure 4.3: Copper wire for HT Figure 4.4: Copper wire for LT
It is not considered that there is any significant material improvement available here.
They use of larger winding conductor cross section to reduce winding resistance and
hence load loss is a possible option for improvement. However larger cross section
conductor will also have the undesired effect of increasing eddy current loss when
harmonic current are present in the winding with nonlinear load. They will also add to the
weight and cost. Lower temperature operation and the attendant lower winding resistance
would reduce load loss, but would mean lower power capacity for the same size
transformer unit.
Insulation Paper:
Electrical insulation papers are paper types that are used as electrical insulation in many
applications due to pure cellulose having outstanding electrical properties. Cellulose is a
good insulator, having a dielectric constant significantly greater than one.

Figure 4.5: Insulation Paper

HT and LT Bushing:
Bushing is an insulated device that enables an electrical transmitter to go securely
through an earthed conducting barrier wall of a transformer. When high voltage
conductor passes through h a metal sheet or frame which is at earth potential, the
necessary insulation is p provided in the form of bushing. This Bushing is comprised of
porcelain material with capacitors set around the wire. So it has that shape, transformer
has two windings inside the core. So we require an association from these two
windings to outside for a additionally utilize.

LT Bushing

HT Bushing

Figure: 4.6: HT and LT Bushing

Tap Changer:
The purpose of a tap changer is to regulate the output voltage of a transformer. Id does
this by substituting the quantity of turns in a single winding and there by changing the
turn proportion of the transformer. The tapings shall be selected by an 'off load' tapping
switch with an e external hand wheel with provision for locking on to a selected tapping.
The voltage operating positions, together with tap change positions might be clearly and
permanently checked. This will also have an impact on transformer losses.

Tap number

Figure 4.7: Off Load Tap Changer

Channel:

Channel need some help. That help is given by the help channel. Channel is a long pole
which is sliced by the size required. But Bacher Engineering Ltd. Bought the channel
from different companies. After the channel reached it sent to the hole drilling section.
After completing the drilling channel it sent to the core section to assemble the core on
the channel. Four channels are needed to make one complete transformer.

Figure 4.8: Channel

Pressboard/Supporter:
Amongst Channel and the core a separator is used for protection. This Guarantees not to
pass any immediate e electric current between them. Hard board is used this for this kind
of protection. This additionally have some other great things like this gives additional
cushion to the core to get any harm by the channel. 5mm thick separator is used for
ensuring the tight bonding between the channel and core. It is sufficiently hard that it
won’t break.

Channel to
Core
supporter

Core

Channel

Figure 4.9: Channel to Core Supporter

Transformer Tank:
The transformer tank should be manufactured from steel and might be of hearty
development. Care should be taken at the assembling stage so as not have leaks during
transportation or when the transformer is continuously worked d at rated power.
Transformer tank envelop the active part, filled with completely with oil. The body has
no contact with the active part. The paint at the inward side is oil resistive and the
external paint is hostile to consumption. Even if it just a container but required much
consideration during design. Except for radiator components, every outside joint should
be crease welded. The bearing surface of the tank to which bushings are clamped should
be significantly level. E very single coordinating face of joints should be made oil tight
and completed with as mood surface to guarantee that the casketing materials make a
satisfactory joint.
 Figure 4.10: Transformer Tank
Radiator:
Radiators are utilized as a part of a transformer to cool the transformer oil through normal
air or forced air streaming in these radiator fins. As the transformer oil temperature goes
down because of cooling it goes to the transformer tank from base, cool the winding and
gets warmed, and afterward come back to the radiator for next Cooling.

Figure 4.11: Transformer Radiator

Transformer Oil:
Transformer oil or protecting oil will be oil that is stable at high temp erasures and has
superb electrical protecting properties. Transformer oil forms an exceptionally critical
part in the transformer protection system. Breakdown voltage strength is the basic
parameter of the transformer oil. Breakdown voltage should not be less than 50 kV after
filtration. The fundamental crude material for the creation of transformer oil is crude
Petroleum.

Figure 4.12: Transformer Oil in drum

Oil Level Indicator:
Oil level Indicator gives nonstop sign of the fluid level within a transformer's primary
tank, conservator tank or load tap changer compartment. This device is needed to give a
visual indication about the insulation fluid level. This device has been designed to give an
alarm in case the fluid reaches the minimum or the maximum level according to the
preset values.

Maximum Level

Normal Level

Minimum Level

Figure 4.13: Oil Level Indicator

Conservator tank:

Conservator tank is transformer oil storage tank. Its function is to ensure that the
transformer tank is completely filled with oil every time. If the main tank oil reduces, the
conservator will feed the oil to main tank and if the oil gets expansion that oil will go to
conservator.

Figure 4.14: Conservator tank

Breather:
Most of the power generation companies use silica gel breathers fitted to the conservator
of oil filled transformers. The purpose of these silica gel breathers is to absorb the
moisture in the air sucked in by the transformer during the breathing process. When load
on transformer increases or when the transformer under full load, the insulating oil of the
transformer gets heated up, expands and gets expel out in to. The conservator tank
present at the top of the power transformer and subsequently pushes the dry air out of the
conservator tank through the silica gel breather.

Figure 4.15: Breather

Temperature meter/thermometer:
These devices are supposed to indicate hottest spot in the winding g based on the
manufacturer’s heat run tests. At best, this device is only accurate at top nameplate rated
load and then only if it is not out of calibration. They are not what their name implies and
can be misleading. They are only winding hottest-spot simulators and n ot very accurate.
There is no temperature sensor imbedded in the winding hot spot. At best, they provide
only a rough approximation of hot spot winding temperature and should not be relied on
for accuracy. They can be used to turn on additional cooling or activate alarms as the top
oil thermometers do.

Figure 4.16: Temperature meter/thermometer:

Horn Gap:
Arcing horn basically protected conductors used the insulators in high voltage.
Transmission Line may damage during flashover. Over voltage on transmission line may
occurs due to various real sons like- lightning strike, sudden load variety on, fault etc.
Due to this high voltage a flash over may take place which will blast the insulator. Horns
are normally paired on either side of the insulator, one connected to the high voltage part
and the other to ground. The horns can take different forms, for example simple
cylindrical rods, circular guard rings.
 Horn Gap

Figure 4.17: Horn Gap

Buchholz Relay:
The Buchholz Relay is a protective device container housed over the connecting pipe
from the main tank to the conservator tank. It is a type of oil and gas actuated protection
relay universally used on all oil immersed transformers having rating more than 750
kVA. It is not provided in relays having rating below 750 kVA from the point of view of
economic considerations. It is used to give an alarm in case of incipient faults in the
transformer and to disconnect the transformer from the supply in the event of severe
internal faults [3].

Figure 4.18: Buchholz Relay

4.4 Transformer Losses

An ideal transformer would have no losses, and would therefore be 100% efficient. In
practice energy is dissipated due both to the resistance of the windings (known as copper
loss), and to magnetic effects primarily attributable to the core (known as iron loss).
Transformers are in general highly efficient, and large power transformers (around 100
MVA and larger) may attain an efficiency as high as 99.75%. Small transformers are
used to power small consumer electronics may be less than 85% efficient. Transformer is
a static device, i.e. we do not get to see any movements in its parts, so no mechanical
losses exist in the transformer and only electrical losses are observed [4]. The various
types of losses are

Losses in the
transformer

No load loss Load loss or Stray Losses Dielectric

o Iron loss Copper loss Losses

Hysteresis Eddy
Losses Current
Losses

No Load Loss or Iron Loss:

Whenever an AC magnetic field is generated in the steel core, it will cause an energy loss
in the core material. This is the “No Load Loss” or “core loss” of the transformer. There
are, in turn, two component of the No Load Loss:
 Hysteresis loss
 Eddy current loss

These both produce heat in the core material they do this in quite different way.
Hysteresis loss is a magnetic loss process whereas eddy current loss is an electrical loss
process.
Hysteresis loss:

Hysteresis loss is created because of the impact of the exchanging magnetic field on the
soft magnetic steel of the core. As the magnetic area in the steel endeavor to take after the
changing induction of the AC magnetic field they create frictional heat in the core; this is
hysteresis loss. Hysteresis losses are strongly material-dependent. For example silicon-
steel has much lower hysteresis loss than normal steel, but mu-metal has a much lower
hysteresis loss than silicon steel (it is also much more expensive). Thus hysteresis loss is
dependent on the frequency of the applied magnetic field, the AC power frequency and
on the particular material utilize for the core [4].

Eddy current loss:

When the flux links with a closed circuit, an emf is induced in the circuit and the current
flows, the value of the current depends upon the amount of emf around the circuit and the
resistance of the circuit. Since the core is made of conducting material, these EMFs
circulate currents within the body of the material. These circulating currents are called
Eddy Currents.

The eddy current losses depend on the electrical resistance of the core material and the
AC frequency. The resistance can be increased and the eddy current loss decreased by
using thin lamination or by using a core material with a naturally high electrical
resistance, such as undefined magnetic metal. Both of these components of core loss are
dependent on the AC frequency at which the magnetic field alternate, so that when
frequency increases, the core loss will increase. Hysteresis loss increases linearly with
frequency but eddy current loss scale as the square of frequency. The eddy current loss is
minimized by making the core with thin laminations [4].

Load loss or Copper Loss:

These Losses happen in the windings of the transformer when heat is scattered because of
the current going through the winding and the inside resistance offered by the windings.
2
So it is also known as Ohmic loss or I R losses, where I is the current going through the
windings and R is the internal resistance of the windings. These losses varied according
to the load and known hence it is also known as variable losses. Copper losses vary as the
square of the load current. Although “copper loss” is a widely used term for Load Loss,
the winding are not always made of copper. In modern distribution transformer, the
secondary winding may be wound in the form of cylindrical sheet of aluminum. This is
an important consideration in adjusting loss for temperature variation.

Stray Loss:

The occurrence of these stray losses is due to the presence of leakage field. The
percentage of these losses is very small as compared to the iron and copper losses so they
can be neglected [4].

Dielectric Loss:

Dielectric loss occurs in the insulating material of the transformer that is in the oil of the
transformer, or in the solid insulations. When the oil gets deteriorated or the solid
insulation get damaged, or its quality decreases, and because of this, the efficiency of
transformer is affected [4].
 Chapter 05: Manufacturing and Assembling Process
5.1 Basic Calculation:

We calculate all the things of 400kVA Transformer

Table 5.1: Basic Calculation

HV LV
Connection Delta Star
type
Line Voltage 11000V 415V
Line Current =(kVA × 1000)/ (√3 × line =(kVA × 1000)/ (√3 × line
voltage) voltage)
=(400 * 1000)/ (√3* 11000) =(400 * 1000)/ (√3* 415)
=20.99A =556.48A

Phase Voltage Line Voltage 415/√3 = 239.6 V

240V

Power P= 400kVA
Primary /line voltage =11000 Volt
Secondary / line voltage = 415 Volt
At first we need to find out the Diameter of a Transformer
1/4
Diameter =3.96*(kVA) [ it can vary from 3.5-4]
1/4
=3.96*(400)

=17.70*10mm [1cm=10mm]
=177mm
We can consider 170mm for rounding process
Let, core width=170mm
The thickness of each stack pertaining to a particular core step is calculated as follows
Now, we need to select the Area,
At first we need to find out per core Area,
A1=Width*thickness
= 170*49
= 8330
A2=160*26
= 4160
A3= 150*19
= 2850
A4= 140*14.34
=2007.6
A5=130*12
=1560
A6=120*14.34
=1720.8
A7=100*16
=1600
A8=80*12
=960
A9=60*8.64
=518.4
Area=total area/100

=23706.8/100

=237.068mm
Per turns voltage = 4.44*f*Bm*A*10-4
[we can select Bm from 1.5-1.7]
-4
= 4.44*50*1.55*237.06*10
= 8.15v
Where, f= frequency
B m= Flux density

A= Area
LT Turns=240/8.15
=29.44
=30
Conductor Area Selected for 400kVA transformer:
Secondary Coil/LT Winding:
Secondary Winding type=Helical Winding

Current density for Cu in Oil Maximum 3.5

Let, We Consider,
Cu Current density =2.64
Here,
We need LV side current=556.48
[We select conductor which current capacity is 557.568 which comes from this equation
calculating value= 8*4.4*6*2.64]
Arrangement of conductor=3*2
Conductor=8*4.4
Insulation=0.5mm
Overall Size of Conductor=8.5*4.9
Total Turns=30
Layer = 2
Per layer turns = 30/2
=15
Inter layer insulation = 0.5mm
In Diameter of coil LV= (177+6) mm
=183mm
Height of the Coil= (8.5*3)*(15+1) [1 coil Extra for Helical Windings]
= 408+ (18+18+6) [Side ring/side gear upper18mm and lower 18mm
= 408+42
[Conductor per turn air gap=6]
∴ Height of the Coil = 450mm
Out Diameter of LV = {(4.9*2)*2 + (4.9*2)*2} +in diameter
=19.6+19.6+183
=222.2 +.8 [layer insulation .8]
=223
Conductor Weight= In diameter+ (Out diameter / 2) [Mid diameter= In dia + Outdia/2]
=183+ (223/2)

=203

=203*3.1416*30 [Length=mid diameter* *LT Turns]

=19132.34*8*4.4*6 [width=8, thickness=4.4,
Conductor number=6]
=4040751.053*0.0000089 [0.000089=constant density of copper]
=35.96*3 [3coil]
=107.88+10[10=starting and finishing lead]
=117.88 kg

Primary Coil/HT Winding:

In Diameter=246 [LT to HT gap 23ml, but we can take maximum 25
∴ Out diameter of LT + gap=223+23=246 in diameter of HT]
Current density=2.82
Primary Current, P=√3VI
 Table 5.2: Standard Size of Copper wire [8]

SWG In mm SWG In mm
1 .300 7.620 21 .032 .813
2 .276 7.010 22 .028 .711
3 .252 6.401 23 .024 .610
4 .232 5.893 24 .022 .559
5 .212 5.385 25 .020 .5080
6 .192 4.877 26 .018 .4572
7 .176 4.470 27 .0164 .4166
8 .160 4.064 28 .0148 .3759
9 .144 3.658 29 .0136 .3454
10 .128 3.251 30 .0124 .3150
11 .116 2.946 31 .0116 .2946
12 .104 2.642 32 .0108 .2743
13 .092 2.337 33 .0100 .2540
14 .080 2.032 34 .0092 .2337
15 .072 1.829 35 .0084 .2134
16 .064 1.626 36 .0076 .1930
17 .056 1.422 37 .0068 .1727
18 .048 1.219 38 .0050 .1524
19 .040 1.106 39 .0052 .1321
20 .036 .914 40 .0048 .1219

For this transformer,

We use 13 SWG = 2.337mm [from the table]

πD^2
Conductor area=
4

= 3.1416×(2.337)2
4

= 4.289
Current density= 2.82A [maximum current density =3.5]
Tapping for 2.5% to -7.5%
Primary turns =LV turns* Ratio

Type of Coil=4 [normal coil 2, Tap coil =2]

We use Super Enameled Copper Wires,
Insulation=0.1mm
Overall Size=2.337+0.1
=2.44
Arrangement of Conductor =1
Height of coil=101
Layer =9
In diameter =246
Out diameter = conductor thickness*layer+ inter layer insulation
= (2.44*2)*9+1.08
=43.92+1.08
=45+246 [246=HT In diameter]
=291mm
Core calculation:
Window height=470 mm [20mm more than LT coil]
Limb center=300 mm [10ml extra from out diameter of HT; it can take maximum

20] Diameter of core =177mm

 Figure 5.1: Details of core A, B, C

Table 5.3: Core plates dimension with quality

S/N Length1 Width Length2 Stack

A Core

A1 470 170 810 49

A2 470 160 790 26

A3 470 150 770 19

A4 470 140 750 14
A5 470 130 730 12
A6 470 120 710 10
A7 470 100 670 16

A8 470 80 630 12
A9 470 60 590 8
B Core

B1 470 170 640 24.5

B2 470 160 630 13

B3 470 150 620 9..5

B4 470 140 610 7

B5 470 130 600 6
B6 470 120 590 5
B7 470 100 570 8

B8 470 80 550 6
B9 470 60 530 4
C Core

C1 130 170 770 49

C2 140 160 760 26
C3 150 150 750 19
C4 160 140 740 14
C5 170 130 730 12
C6 180 120 720 10

C7 200 110 700 16

C8 220 100 680 12

C9 240 90 660 8
5.2 Cutting Core:

After calculating the measurement of core we cut the core by using different machine to
get our required shape. The core is made of Cold-Rolled High Grained Oriented (CRGO)
0 0
silicon steel. The core cut of an angle 90 in rectangular shape and 45 for MITRED
shape also cut “V” notch. Staking and Wound core 0.27 mm thick M4 grade silicon steel.

Figure 5.2: Cutting Core

5.3 Core Assembling :
The cores mitered and as assembled in step lap formation. The mitered joins
are provided with minimum gap. The clamping structure is a fabricated steel
frame made from standard angle, channels or plate construction.

Figure 5.3: Core Assembling

After arranging the core we tight up the core with 4 channel and tie the rods. A fret tight up the
core cotton tape will be spray end shown in fig. After tighten up the core, the upper two channels
and C core is open for placing the two coils (LT and HT) in to the core. Before placing the core,
above the cotton tape there is 6mm insulation paper is wrapped into two parts (3mm+3mm);
which is used for insulation between core and coil and give a bottom separator inside the three
cores which separated between coil an d channel.

C Core is
Open

Insulation
paper

Bottom
Separator

Figure 5.4: cotton tap rayed above core Figure 5.5: Insulation paper
and bottom Separator
5.4 Coil Windings:
There are two windings wound over the transformer core which is protected from each
other. Windings consists of few turns of copper coils packaged together an every package
are associated in series to form of windings.

The low voltage winding is in cylindrical shape, the high voltage winding is in cylindrical or
foil type. HT & LT windings are nothing but the calculated coil form of copper wire. So it
will have sufficient capacity secured against short circuit and make the magnetic circuit more
reasonable. The winding conductor is drawn to various sizes in round and rectangular shapes.
The choice of conductor and insulation covering depend on the voltage class, current, cooling
and insulation clearances. The cross section of the winding provides the necessary area to
handle the current. The conductor is wound into coils.

The windings are such designed so as to ensure reduced axial stresses in Short Circuit
conditions and also to withstand impulse and over-voltages. Some standard forms of coil
windings are spiral, helical, interleaved disc and plain disc. For Power Transformers, both
low voltage and high voltage windings are disc type, which give highest resistance
against short circuit forces. It is ensured that proper tension is given on the winding for
rigidness.

Figure 5.6: HT Windings at high Figure 5.7: LT Windings at Low Voltage

Voltage Coil windings machine Coil Windings Machine
5.5 Core Coil Assembling:
The transformer experiences dynamic forces due to frequent loading and unloading. The
sudden loading and withdrawal of load creates a tensile stress on the winding in the form
of buckling forces or bursting forces. The construction of the CCA (Core Coil Assembly)
by providing sufficient radial and axial supports prevents the stress from causing any
damage to the windings.

Fig No 5.8: Core Coil (HT & LT) Assembling

After placing the coil in the core it look like fig 5.8. Head of the leg is tight by cotton and
then again press board i s placed top of the coil for insulation between coil and upper
channel. Press board is cut according to the space between one core legs to other leg.
After placing the press board C type of core is placed in the core legs to complete core
designs.

Figure 5.9: Placing the C core in core legs

After finishing the core placing, it is tights by upper channel. Tie rod is used for
balancing the core leg.

5.6 Tap changing:

Tap change from + 2.5% to -7.5%

st
For our 1 value we pick up tap after 2.5% of total turns for 10V more or less. Because
we know primary voltage always not same sometimes it may vary. It will regulate the
output voltage by altering the number of turn and thereby changing the turn’s ratio of the
transformer. We brought out 1 wire after every 32 turns from the total turns of High
tension winding, after turn out six wires form four steps we will connect those by a tap
changer from 1 to 5 tap.
Generally the Transformers are either to Y or Y to connect. If High voltage side Delta
connected then low voltage side Y connected and vice versa. We connected HT side is
Delta connection and LT side is Wye/star connection.
Figure 5.10: LT side with LT Side Bushing Figure 5.11: HT side with HT Bushing

After arranging all these things finally the input and output points are connected with the
copper bars. Copper bars are covered very tightly with cotton tape after welding. Then
the transformer is ready to go for the next step of attaching bushing materials and for
going to heat chamber.

5.7 Heat Chamber

Heating chamber is a place where heat generates. It can controls temperature inside the
heat of the transformer. We can place 3 transformers inside this Heat chamber at a time.
Transformer is placing inside the heat chamber. Transformer is placing inside heat
chamber because of increasing insulating resistance.

Figure 5.12: Heat Chamber

Inside the transformer, coil creates magnetic flux so that heat will produce. If inside of
the transformer is not dry enough, then dielectric strength breaking down because of heat
and power losses occurs. For that reason it needs to dry enough the transformer.
0
Transformer is kept inside the heat chamber for 48 hours at 90 C. This heat chamber
0
temperature range 80 to 100 C.
 Chapter 06: Transformer Testing

6.1 Oil test:

Testing Method: Electric Breakdown Voltage
Oil Brand Name: Transol Savita
At the time of oil testing we takes oil in a pot then give it to oil test machine. It shows the oil
breakdown voltage. We do the same things 5 times and find out the Mean Breakdown voltage.

Table 6.1: Oil test statics

Sample Electric Breakdown Withstand Mean Remarks

No voltage Gap(mm) Time(sec) Breakdown
voltage

01 2.5mm 38kV 30 sec 42.8 Satisfactory

02 2.5mm 40kV 30 sec

03 2.5mm 42 kV 30 sec

04 2.5mm 46 kV 60 sec

05 2.5mm 48kV 60 sec

2.5mm Gap

Figure 6.1: Oil Test Machine

6.2 Measurement of Voltage Ratio:
Measuring the voltage ratio we use voltage ratio test machine. At first we need to set the
ratio meter and multiplier. Then we connect the wire in three phases off the transformer
and match the measured ratio with the calculated ratio.

T able 6.2: Voltage Ratio Test Value

Tap HT LT Calculation Measured Ratio

Position Voltage Voltage Ratio
Phase- Phase- Phase-
H1 H2 H3

1 11275 415 47.04 47.04 47.04 47.04

2 11000 415 45.9 45.9 45.9 45.9

3 10725 415 44.75 44.75 44.75 44.75

4 10450 415 43.63 43.63 43.63 43.63

5 10175 415 42.54 42.54 42.54 42.54

Figure 6.2: Voltage Ratio Test set

Remarks: The Voltage Ratio between HT & LT side of the Transformer

**Voltage Ratio is measured by Raytech USA (TR SPY Mark II) Manufactured by USA.
6.3. Resistances Test:
For resistance test, Firstly we need to conduct the meter to measure H.T side resistance
then we just hold on the probe of the clamp on meter to the HT lead like - AB, BC, CA
and find the result for this side. We should repeat same procedure for getting the result of
LT side also.

A) H.T Winding: AB = 5Ω; BC= 5Ω ; CA= 5Ω

B) L.T Winding: ab = 1.62Ω; bc=1.62Ω ; ca= 1.62Ω

6.4 Insulation Resistance/ Megger Test

When we do the insulation test of a transformer at first we hold on the probe of HV side
with Earthing, then LV side with Earthing and then HV side with LV side for 30 second.
We do the same things again for 60 second. By doing this process we get the values
which is shown to the tab le 6.3.

Figure 6.3: Insulation Resistance / megger test

Table 6.3: Insulation test value

Insulation Resistance (Giga Ohm)

TIME HV-E LV-E HV+LV

30 sec 35G Ω 36 GΩ 32 GΩ

60sec 41 GΩ 41 GΩ 50 GΩ
6.5 High Voltage Test:

For doing High Voltage test at HV winding we need to short the three phase terminal of
HV side, LV side and body/tank with the main earthing. At first we have given 28kV
from High voltage test bench, then it come to Barrier. After that it was gone through high
voltage transformer’s HT side. We have to apply the 28 kV for 1 min too the transformer.
If the transformer remains withstand after keeping this voltage for 1 m in then it proves
that the transformer keep secure in voltage surges which may be caused by lightning or
other over voltage.

Figure 6.4: High Voltage Test bench Figure 6.5: Barrier

Figure 6.6: Transformer HV side shorted & Figure 6.7: High voltage transformer
LV side and tank shorted with earthing.
 Chapter 07: Conclusion

7.1 Conclusion:

Bachar Engineering Limited is one of the leading manufacturers of transformers and

electrical products in Bangladesh. It produces high quality products which ensure modern
design facilities. we had wonderful experience at our internship which helped me find the
relationship between theoretical and practical knowledge. I had visited the factory and
collect all the required data instructed by supervisor & talked with the technicians about
the process of manufacturing, assembling and other pros and corns about transformers.
we always observed every single step of transformer manufacturing, assembling and
testing process very carefully. I tried to give my best effort to know all the related terms
about transformers from the company. The stuffs of the company are so co-operative &
they provide all the necessary information which is needed by me. If we faced any
difficulties I had discussed with them. They are manufacturing transformer by
maintaining high level of accuracy with best level of effort to make incredible quality
products. Although, their
testing level is not enough standard, it will require more quality level of testing machines
to develop this process.

In our power system transformer plays an important roles for the industry. In our modern
industrial economy substation is needed for maintaining electrical sections. A substation
without transformer is not possible because it is necessary to step up or step down voltage
level according to our requirements.
7.2 Recommendation:
Within my internship period, I gather all practical knowledge about transformers manufacturing
from Bachar Engineering Limited. Although, they need to increase some facilities -

The Company mainly use manually operated machines in every section of transformers
which takes more times and more labor cost. They should use digital machines for their
betterment.
They have not enough technicians and manpower as a result they can’t deliver
huge amount of products at a time. So, they should appoint more manpower. They
did not have enough spacing facilities for keeping their products. They need to
increase those facilities also.
They have many transformer test functions. But some of them are carried out at
the time of manufacturing. They should increase their testing number for more
accurate efficiency.
They did not have sufficient amount of testing meters. So, they should increase
the amount of testing meters.
References:

1. BL Thereja, A. T.Thereja (2015-16). A textbook of electrical technology (23

ed., Vol. II). New Delhi, India: S Chand & Company LTd.

2. Harlow, j. H. (Ed.). (2012). Electrical Power Transformer Engineering (3

ed.). Broken Sound Pkwy NW: Taylor and francis Group.

3. V.K MEHTA, R. M. (2014-15). Principles of power system (4 ed.).

RAM NAGAR,NEW DELHI, INDIA: S. CHAND.

4. Circuit Globe. (n.d.). Retrieved November 10, 2017, from Types of Losses
in a Transformer: http://circuitglobe.com/types-of-losses-in-
transformer.html

5. Windows to the Universe. (n.d.). Retrieved November 7, 2017, from The Role
of Transformer in out Electrical Power System:
https://www.windows2universe.org/physical_science/physics/electricity/
transfor mers_in_power_grid.html&edu=high

6. Basic Power Engineering LTD. (n.d.). Retrieved November 28, 2017, from
Mission, http://www.bpelbd.com/about.html
7. Custom Coils. (n.d.). Retrieved 11 10, 2017, from
https://www.customcoils.com/ images/single-phase-transformer-
schematic.jpg

8. https://en.wikipedia.org/wiki/ Standard wire gauge.

9. BPEL Manual Guide