Ramaiah: Department of Technical Education

DEPARTMENT OF TECHNICAL EDUCATION
RAMAIAH POLYTECHNIC
BENGALURE-560054
INPLANT TRAINING
RAMAIAH
SUBMITTED BY
CHARAN.V
(476EE17011)
VI SEM ELECTRICAL AND ELECTRONICS ENGINEERING
UNDER THE GUIDANCE OF
Ms. GNANESHWARI.V
(LECTURER
E&E DEPARTMENT)
DIPLOMA IN ELECTRICAL AND ELECTRONICS

ENGINEERING
Prescribed by the Board of Technical Education
(2019-2020)
DEPARTMENT OF TECHNICAL EDUCATION
RAMAIAH POLYTECHNIC
BENGALURE-560054
ELECTRICAL AND ELECTRONICS DEPARTMENT
CERTIFICATE
RAMAIAH
This is to certify that Mr. …………………………… has satisfactorily completed the

course on IN-PLANT TRAINING in ELECTRICAL AND ELECTRONICS
ENGINEERING programme prescribed by the Board of Technical Education,
Government of Karnataka, and there by submitted the report during the
year (2019-20)
Signature of the Head of the Department Signature of the Course Coordinator

ACKNOWLEDGEMENT
We show our grateful thanks and respect to Smt. MANGALA GOWRI,

Principal, RAMAIAH POLYTECHNIC for her help and co-operation in pursuing
my studies.
Our sincere thanks to our Mr. H.R.SRIDHAR ,HOD, Dept. of Electrical and
Electronics for his support and co-operation.
Our heart full respect and thanks to Smt. GNANESHWARI.V ,

LECTURER(guide) (E&E) for her effort and involvement to have made all the
students successfully complete their inplant training.
Our special thanks to Sri Sairam Power Controls proprietor

Mr. HEMANTH OJHA for his support, love and care for us and also Sri Sairam
Power Controls team for helping us to get into industrial environment and
gain some knowledge about it.
(Signature)
Name :………………………..
Reg no:……………………….
CONTENTS
Sl No Content Page No
1 Introduction of company 1-2
1.1 History
2 Introduction of Transformer 3-6
2.1. Introduction
2.2. Principle of Transformer
2.3. Types of Transformer
2.4. Parts of Transformer
3 Manufacturing Process of Transformer 7-21
3.1. Winding Construction

3.2. Core Assembly
3.3. Core & Winding Assembly
3.4. Tapping & Tap Changer
3.5. Drying Process
3.6. Tank Construction & Radiator
3.7. Tanking Breathers & Final Fitting
3.8. Painting
3.9. Testing
4 Summary 22
Inplant Training report On Transformer Manufacturing
1 INTRODUCTION ABOUT “Sri Sairam Power

Controls”
1.1 Company Profile And History:-
Incepted in the year 2006, "Sri Sairam Power Controls" has emerged
as the reliable manufacturer and supplier of impeccable range of Electrical
Power Transformers. Our range includes High Power Transformers,
Universal Power Transformers, Electrical Power Transformers,
Distribution Transformers, Electrical Transformers and Industrial
Transformers. Catering to the diverse needs of various industries our range is
highly appreciated for high performance, tolerance, corrosion resistance and
low maintenance.
Ever since our establishment, we have maintained a relentless pursuit of

improvement through ethical business practices and modern production
techniques. Our team has immense expertise in the field allowing us to
maintain world-class quality standards, efficient delivery schedules and
excellent after sales services. Our R& D team with their constant product
upgradation and market knowledge enables us to meet the requirement of
client as per their specifications. Under the able guidance of our mentors Mr.
Jayesh, Mr. Jayaseelan, Mr. C. Ramesh and Mr. Hemanth Ojha we have
reached pinnacle of success within a short span. Their immense expertise has
enabled us to carve a niche for our wide range of products and services.
Department Of Electrical & Electronics Page 1

SRI SAIRAM POWER CONTROLS

ISO 9001:2008

2 INTRODUCTION OF TRANSFORMERS
2.1 WHAT IS TRANSFORMER?
A transformer is a device that transfers electrical energy from one circuit to

another through inductively coupled conductors—the transformer's coils. 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 field induces a varying electromotive force (EMF), or
"voltage", in the secondary winding. This effect is called inductive.
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 number of turns in the secondary (Ns) to the number of turns in the primary (Np) as
follows:
2.2 PRINCIPLE OF TRANSFORMER
The transformer works on the principle of ‘MUTUAL INDUCTION’.

An alternating flux in the primary coil will create an alternating flux in the
transformer core, which is linked with the other coil which produces a mutually
induced emf according to faraday’s laws of electromagnetic induction.
A current flowing through a coil produces a magnetic field around the coil. The
magnetic field strength H, required to produce a magnetic field of flux density B, is
proportional to the current flowing in the coil.

A Current in the primary winding produces a magnetic field in the core. The
magnetic field is almost totally confined in the iron core and couples around through
the secondary coil. The induced voltage in the secondary winding is given by
Faraday’s law
2.3 TYPES OF TRANSFORMER

 Power Transformers
 Mobile Transformers
 Distribution Transformers
2.4 PARTS OF TRANSFORMER

Transformers are used to transfer electrical energy from one circuit to another
through electromagnetic induction. They are used either to step up or step down
voltage levels. A transformer is made of several different parts that function in their
own different ways to enhance the overall functioning of a transformer. These include
core, windings, insulating materials, transformer oil, tap changer, conservator,
breather, cooling tubes, Buchholz Relay and explosion vent. The core, windings,
insulating materials and transformer oil are seen in almost every transformer, while
the other components are seen in transformers that are more than 50 KVA.
 Core
The core of the transformer is used to support the windings. It is made of soft
iron to reduce eddy current loss and Hysteresis loss, and provides low reluctance path

to the flow of magnetic flux. The diameter of a transformer’s core is directly

proportional to copper loss and inversely proportional to iron loss.
 Windings
Windings consist of several copper coil turns bundled together, each bundle
connected to form a complete winding. Windings can be based either on the input-
output supply or on the voltage range. Windings that are based on supply are
classified into primary and secondary windings, meaning the windings to which the
input and output voltage is applied respectively. On the other hand, windings based on
voltage range can be classified into high voltage and low voltage windings.
 Insulating materials
Insulating materials like papers and card boards are used to isolate primary
and secondary windings from each other as well as the transformer core. These
windings are made of copper due to high conductivity and ductility. High
conductivity minimizes the amount of copper needed and minimizes losses.
Moreover, high ductility results in easy bending of conductors into tight winding
around the core that also minimizes the amount of copper and volume of winding.
 Transformer oil
The transformer oil insulates as well as cools the core and coil assembly. The
core and windings of the transformer must be completely immersed in the oil that
normally contains hydrocarbon mineral oils.
 Conservator
The conservator is an airtight metallic cylindrical drum fitted above the

transformer that conserves the transformer oil. It is vented at the top and is filled only
half with the oil to allow expansion and contraction during temperature variations.
However the main tank of the transformer with which the conservator is connected is
completely filled with the oil through a pipeline.

 Breather
The breather is a cylindrical container filled with silica gel, which is used to
keep the air that enters the tank moisture-free. This is because the insulating oil when
reacts with moisture can affect the insulation and cause internal faults, which is why it
is a must to keep the air free from moisture. In the breather, when the air passes
through the silica gel, the moisture contents are absorbed by the silica crystals.
 Tap changer
To balance voltage variations within the transformer, tap changers are used.
There are two types of tap changers – on load and off load. In on load tap changers,
tapping can be changed without isolating transformer from the supply, while in off
load, the transformer needs to be disconnected from the supply.
 Cooling tubes
As the name suggests, cooling tubes are used to cool the transformer oil. The
circulation of oil within the transformer may be natural or forced. In the case of
natural circulation, when the oil temperature rises, the hot oil naturally moves to the
top and cold oil moves down, while in case of forced circulation, an eternal pump is
used.
 Buchholz Relay
Placed over the connecting pipe that runs from the main tank to conservator
tank the Buchholz Relay senses the faults occurring within the transformer. It operates
by the gases emitted due to decomposition of transformer oil during internal faults.
Thus, this device is used to sense and in turn protect the transformer from internal
faults.
 Explosion vent
The boiling hot oil from the transformer is expelled during internal faults
through the explosion vent to avoid explosion of the transformer. This is generally
placed above the level of the conservatory tank.

3 MANUFACTURING PROCESS OF TRANSFORMER

 Winding Construction
 Core Assembly
 Core & Winding(Coil) Assembly (CCA)
 Tapping &Tap Changer
 Drying process
 Tank Construction
 Tanking & Final Fitting
 Painting
 Testing
3.1 Winding Construction:-
Conducting material is used in the windings of the transformer. Usually

the windings are in concentrically to minimize the flux leakages. Transformer
windings are designed to meet three fundamental requirements, viz. mechanical,
thermal and electrical. They are cylindrical in shape and are assembled concentrically.
Paper insulated conductors of high conductivity & soft drawn E.C. Grade copper is
used which comply with the latest Indian as well as international Standards.

Windings are made with great care by well experienced skilled workers in dust free &
temperature controlled environment.
Insulation between layers and turns is based upon the electrical and mechanical
strength level. Interlayer cooling ducts (Axial & Radial) are provided to minimize the
temperature gradient between windings and oil, and hence the hot spot temperature is
kept to a minimum. This also ensures that the rate of insulation deterioration is
minimized and high life expectancy is achieved.
Transpositions are made in multiple conductor windings, to ensure uniform current

distribution, minimize circulating currents, decrease eddy current loss and improve
the lamination factor.
3.2 Core Assembly:-
Core is built with Cold Rolled Grain Oriented Silicon Steel, low loss silicon
steel lamination. Bonded core design/ technique is used to eliminate hole punching
and to minimize fixed losses and Magnetizing Current. Use of HiB grade & Laser
scribed Laminations and Rigid clamps significantly reduce vibrations and noise level.
Cooling ducts are provided in large transformers for efficient circulation of oil to keep

temperature of core well within limit without affecting the flux distortion and also in
the core suitable insulation paper are inserted between some laminations for the
purpose of reducing eddy currents and also minimizing magnetic short circuit. Core
of the transformer is either in square or rectangular in size. It is further divided into
two parts. The vertical position of the core is limbs and horizontal position of the core
is yoke of the core. Core is made up of laminations to reduce the eddy current losses
get minimized. This lamination is insulated by using insulations line varnish or thick
paper. Paper insulation is used for low voltage transformer and varnish is used for
high voltage transformer.
3.3 Core & Winding(Coil) Assembly (CCA):-
L.V. Windings are normally placed near core over insulating cylinder and oil
ducts. HV Windings are assembled co-axially placed with respect to LV. Spacers
between coils are 'T' shaped for added firmness. Coils are assembled with best
insulating materials and are adequately clamped. . SPA methodology is now a day
widely adopted to have it's special beneficial characteristics. The winding is rigidly
supported by a common spacer ring of densified wood at the top and bottom for

precise alignment. Well profiled angled rings are placed between LV & HV windings
to reduce voltage stress level. The ends & tapping leads of all windings are connected
by special extra flexible, insulated copper cables which are rigidly braced in position.
3.4 Tapping &Tap Changer:-
Generally Taps are provided on HV Windings for HV Variation or LV

Variation as specified by customer. These are brought up to a gang operated switch,
suitable for external manual operation and can be locked in any desired position to
avoid unauthorized operation.
All the moving contacts are spring loaded to ensure proper pressure and good
contacts. To achieve precise voltage regulation on load tap changer is used instead of
OCTC. Usually Higher capacity transformers i.e above 5000 KVA ratings, can be
supplied with On Load Tap Changer along with necessary controls to make it suitable
for manual, local electrical or remote Electrical operation.

3.5 Drying Process:-
The core- coil assembly is placed in Vacuum Auto Enclave to eliminate

moisture content which is targeted less than 0.5 % moisture. Drying process is to be
carried out at 90°C & respective vacuum cycle at rated interval to improve Insulation
resistance and remove ingress of moisture in insulation material

3.6 Tank Construction & Radiators
Small capacity tanks are fabricated from sheet steel while larger ones are
assembled with cast aluminium. For cooling purpose the tank is welded with cooling
tubes. These are some types of transformer tanks.
Protection of active part in transformer is very important. While achieving the

optimized size of transformer to suit the site condition for installation. The main role
of the tank is to protect the active part and tank is manufacture to have sufficient
strengths to withstand internal & external faults that may occur during operation.
Tanks are fabricated from low carbon M.S. Sheet of best quality proceed by qualified
welders. The tank is designed to withstand vacuum and pressure test as per Indian /
International standards. A robust skid under base is provided, and guide bars are
located inside the tank to securely fix the core and windings assembly in position, and
to prevent any movement during transportation.

Radiators
(i) Radiators are to be assembled only one at time.

(ii) Oil required to fill in the radiators is sent separately in drums. Test oil sample
from each drum for BDV. Ensure it is more than minimum specified in I.S.
1866 for New Transformer.
(iii) Fill the conservator full using an oil filter machine, if available.
(iv) Clean one radiator externally. Remove blanking plates and clean the gaskets
and radiator flanges. If gaskets are damaged, use spare gaskets.
(v) If blanking plates are not in position and it is suspected that foreign material
might have entered the radiators, clean them internally by flushing fresh and
clean transformer oil

3.7 Tanking, Breathers & Final Fitting:-
Dried out Core & Coil Assembly is tightened before application of hot oil
shrinkaging for 24 hours. The oil shrinkaging process avoids looseness of active parts
during it's service at site. At last uniform pressing is done on Core & Coil Assembly.
High mechanical rigidity is achieved by hydraulic pressing at circulated force and
tightening all pressure screws.
After completion of Core & Coil Assembly insertion in tank, hot, degassed oil is
then allowed into the transformer tank under vacuum. This oil is then circulated
through the transformer and the oil degassing plant until all gas trapped in the core,
windings, and the insulation is removed. This ensures a high degree of stability in the
insulation structure and early attainment of its mature condition, which would not
otherwise be achieved until the transformer had been in service for some time.

The transformer is made ready for testing after assembly of bushings,

conservators, radiators & all other protective devices .All the joints are gasketed to
avoid leakage with the help of rubberized cork sheets/Nitrite Rubberized ORing,
which can withstand high oil temperature and do not deteriorate nor contaminate oil
in its contact.
Breathers
Breathers also in the “Commissioning Report”. Check that the colour of silica Gel
in Main Breather is Blue. Remove the rubber cap closing the breather pipe and fit the
breather. Fill oil in the oil cup and remove the seal which closes the breather opening.
Similarly mount the breather.

3.8 Painting:-
Metal which has been pre-treated by means of shot blasting to remove rust and
welding scale is thoroughly cleaned, and then a coat of epoxy zinc chromate primer
paint is immediately applied to all external surfaces. This anticorrosive primer has
rust inhibitive properties and excellent chemical resistance. Two coats of Epoxy or
PU paint , which is highly resistant to chemicals and oil, are then applied. Inside
surface of the tank is applied with HOR paint.
3.9 Testing:-
There are 8 different tests commonly applied to power transformers. Most testing
routines will include most of these tests.

 Turns Ratio Testing
The transformer turns ratio test is used to make sure that the ratio between the
windings of the primary and secondary coils follow the proper specifications. This
test ensures that the transformer will provide the proper step-up or step down in
voltage.
The turns ratio is calculated by dividing the number of turns in the primary
winding by the number of turns in the secondary coil. This calculation defines the
expected output of the transformer and gives the corresponding voltage required on
the secondary winding. In a step-down transformer designed to reduce the voltage, the
number of turns in the secondary coil must be lower than in the first, while in step-up
transformer, the secondary coil must have more turns than the first coil.
The ratio is calculated under no-load conditions, using a tool known as a turns
ratio tester. Done correctly, the test can identify tap changer performance, shorted
turns, open windings, incorrect winding connections and other faults inside
transformers.
Simultaneous readings of voltage are taken to the low-voltage and high-voltage

windings area after the voltage is applied to one winding. The ratio is the division
between the high reading and low reading. If it is a three-phase transformer, each
phase is tested individually.
 Insulation Resistance Testing
Commonly known as the Megger test, insulation resistance testing measures the
quality of insulation within the transformer. Testing is typically done with a
megohmmeter, a tool similar to a multi-meter but with a much higher capacity. Some
variations in testing results in natural, depending on the moisture, cleanliness and the
temperature of the insulation, but to pass, the insulation must demonstrate a higher
resistance than prescribed international standards for the type of transformer.
The insulation resistance test involves measuring the insulation resistance of a

device while the phase and neutral are short-circuited together. It is recommended that
tank and core should always be grounded when this test is performed and that each

winding is short-circuited at the bushing terminals. Resistances are then measured

between each winding and between all other windings and ground.
 Power Factor Testing
The power factor test determines the power loss of the transformer's insulation
system by measuring the power angle between an applied AC voltage and the
resultant current. Power factor is defined as the cosine of the phase angle between
voltage and current. For ideal insulation, the phase angle is 90 degrees, but in practice,
no insulation is ideal. The closer the phase angle is to 90 degrees, the better the
insulation.
The test is performed with a power factor test kit, and the connections are the
same as for the Megger test (the insulation resistance test). This test can be repeated
during the service life of the transformer and verified against the result obtained
during manufacturing, as a check to determine if the insulation is malfunctioning or
decaying.
 Resistance Testing
Resistance testing is conducted several hours after a transformer has stopped

conducting current when it reaches the same temperature as its surroundings. The
purpose of this test is to check for differences in resistance between windings and
opens in the connections. This test ensures that each circuit is properly wired properly
and that all connections are tight. Resistance testing is performed using a transformer
ohmmeter.
Winding resistance is calculated by measuring the voltage and current

simultaneously—ideally, the measured current will be as close to the rated current as
possible. Performing this test will allow you to calculate and compensate for load
losses as a whole.
 Polarity Testing
Polarity refers simply to the direction of current flow in a transformer, and testing
is done to ensure that the windings are all connected the same way, and not in

opposing ways that can cause a short circuit. Polarity is a vital concern if several
transformers are to be paralleled or bank-connected.
Polarity in a transformer is categorized as either additive or subtractive, and it is

tested using a voltmeter. When voltage is applied between the primary bushings and
the resultant voltage between the secondary bushings is greater, then it means that the
transformer has additive polarity. Three-phase transformers are also checked for
polarity by the same means.
 Phase Relation Testing
This test will detect if two or more transformers have been connected in a correct
phase relationship. This test calculates the angular displacement and relative phase
sequence of the transformers and can be conducted at the same time as ratio and
polarity tests. The voltages of the phase of primary and secondary windings in each
transformer can be recorded and comparisons made to get the phase relation between
them.
 Oil Tests
The oil that provides insulation and cooling properties for a transformer should be
tested before the transformer is energized, and periodically as a part of a regular
maintenance schedule. It is generally done with a portable testing unit which applies
test voltage that increases in intensity until a breakdown point of the oil is detected.
An oil sample test can detect several things on a transformer:
 Acid number
 Dielectric breakdown
 Power factor
 Moisture content
 Interfacial tension
Oil tests are very useful for determining the condition of the insulation and the
oil. Based on these results, a maintenance program for the transformer can be
established.

 Visual Inspection
Although this is the simplest of all tests, a visual inspection may reveal potential
problems that can't be detected by other, more sophisticated forms of diagnostic
testing. A standard procedure must be established to perform the visual test,
identifying the elements to be viewed and criteria for pass/fail judgments. These can
vary, depending on the type of transformer and the circumstances of the installation,
but most standard visual inspections look for the presence of manufacturer's labels,
signs of physical damage, the condition of welds, oil loss or leakage, integrity of wire
connections, and the condition of valves and gauges.
 OC & SC Test

At this station, the transformer are undergo through O.C test and S.C test for
efficiency of transformer. The reason for doing these test to calculate losses of the
transformer.
The results of the test can be seen through observation of fault in transformer
operator room in the company

4 SUMMARY
The training of which manufacturing of transformer company was very help full
to me. It has improved my theoretical concept of transformer. We also know that
a transformer is a device that transfers electrical energy from one circuit to another
through inductively coupled conductors—the transformer's coils .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 field induces a varying electromotive force (EMF), or "voltage", in the
secondary winding. This effect is called inductive. The training was more than hope
to me and also help me to understand about manufacturing of transformer more.

Ramaiah: Department of Technical Education

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DEPARTMENT OF TECHNICAL EDUCATION

VI SEM ELECTRICAL AND ELECTRONICS ENGINEERING

UNDER THE GUIDANCE OF

DIPLOMA IN ELECTRICAL AND ELECTRONICS

Prescribed by the Board of Technical Education

ELECTRICAL AND ELECTRONICS DEPARTMENT

This is to certify that Mr. …………………………… has satisfactorily completed the

Signature of the Head of the Department Signature of the Course Coordinator

We show our grateful thanks and respect to Smt. MANGALA GOWRI,

Our heart full respect and thanks to Smt. GNANESHWARI.V ,

Our special thanks to Sri Sairam Power Controls proprietor

3.1. Winding Construction

1 INTRODUCTION ABOUT “Sri Sairam Power

1.1 Company Profile And History:-

Ever since our establishment, we have maintained a relentless pursuit of

Department Of Electrical & Electronics Page 1

SRI SAIRAM POWER CONTROLS

Department Of Electrical & Electronics Page 2

2.1 WHAT IS TRANSFORMER?

A transformer is a device that transfers electrical energy from one circuit to

2.2 PRINCIPLE OF TRANSFORMER

The transformer works on the principle of ‘MUTUAL INDUCTION’.

Department Of Electrical & Electronics Page 3

2.3 TYPES OF TRANSFORMER

2.4 PARTS OF TRANSFORMER

Department Of Electrical & Electronics Page 4

to the flow of magnetic flux. The diameter of a transformer’s core is directly

The conservator is an airtight metallic cylindrical drum fitted above the

Department Of Electrical & Electronics Page 5

Department Of Electrical & Electronics Page 6

3 MANUFACTURING PROCESS OF TRANSFORMER

3.1 Winding Construction:-

Conducting material is used in the windings of the transformer. Usually

Department Of Electrical & Electronics Page 7

Transpositions are made in multiple conductor windings, to ensure uniform current

3.2 Core Assembly:-

Department Of Electrical & Electronics Page 8

3.3 Core & Winding(Coil) Assembly (CCA):-

Department Of Electrical & Electronics Page 9

3.4 Tapping &Tap Changer:-

Generally Taps are provided on HV Windings for HV Variation or LV

Department Of Electrical & Electronics Page 10

3.5 Drying Process:-

The core- coil assembly is placed in Vacuum Auto Enclave to eliminate

Department Of Electrical & Electronics Page 11

3.6 Tank Construction & Radiators

Protection of active part in transformer is very important. While achieving the

Department Of Electrical & Electronics Page 12

(i) Radiators are to be assembled only one at time.

Department Of Electrical & Electronics Page 13

3.7 Tanking, Breathers & Final Fitting:-

Department Of Electrical & Electronics Page 14

The transformer is made ready for testing after assembly of bushings,

Department Of Electrical & Electronics Page 15

Department Of Electrical & Electronics Page 16

 Turns Ratio Testing

Simultaneous readings of voltage are taken to the low-voltage and high-voltage

 Insulation Resistance Testing

The insulation resistance test involves measuring the insulation resistance of a

Department Of Electrical & Electronics Page 17

winding is short-circuited at the bushing terminals. Resistances are then measured

 Power Factor Testing

Resistance testing is conducted several hours after a transformer has stopped