A Practicum Report on

Design and Assembly of 100KVA

Transformer

Md Shantanu Kayser Kanak

Program: BSEEE
ID# 13105157

Department of Electrical and Electronic Engineering

IUBAT–International University of Business Agriculture and
Technology

i
 Assembling of 100 kVA Transformers at Bashar
Engineering Limited

Md. Shantanu Kayser

Kanak ID:13105157
Program: BSEEE

…………………… ………………….. ...…………………

Md Aziz Ul Huq Engr Md Abul Bashar Dr. Md. Shariful Islam
Supervisor Coordinator Chairperson

Department of Electrical and Electronic Engineering

IUBAT-International University of Business Agriculture and Technology

ii
 Letter of Transmittal

20, August, 2019

Engr Md Abul Bashar

Professor and Coordinator
Department of Electrical and Electronic Engineering
IUBAT-International University of Business Agriculture and Technology Sector-10, Uttara Model
Town Dhaka-1230

Subject: Submission of Practicum Report

Dear Sir,
It is a great pleasure for me to submit the final practicum report titled “Design and Assembling of
100 KVA Transformers at Bachar Engineering Limited" as a partial fulfillment of the requirements
of Electrical and Electronic Engineering (BSEEE) from IUBAT. I have tried my level best to make
the report standard by maintaining the guidelines provided from the department.
Thank you very much for giving me the chance and essential guidance as well as direction required
to prepare this report.

I prompt my heartiest gratitude to you to go through this report and make your valuable comments.
Yours Sincerely,

------------------------
Md Shantanu Kayser Kanak
ID: 13105157
Program : BSEEE

iii
Certificate

iv
 Student’s Declaration

The practicum report titled "Design and assembling of 100KVA Transformers at Bashar
Engineering Limited " has been prepared under the supervision of Professor Aziz Ul Huq,
Department of Electrical and Electronic Engineering, IUBAT – International University
of Business Agriculture and Technology as a partial fulfillment of the requirements of
Bachelor of Science in Electrical and Electronic Engineering (BSEEE) from IUBAT for
the fulfillment of the course EEN-490. The contents of this report are the results of
original data and have not been submitted elsewhere for a higher degree to any other
university or institution.

……………….………….

Md Shantanu Kayser Kanak

ID:13105157
Program: BSEEE

v
 Executive Summary

I have completed my internship in Bachar Engineering Ltd recently. Bachar Engineering Ltd
produces different kVA ratings transformers and switch gears. There are several section in the
company, In the machine shop the transformer bodies are produced, this section includes cutting
metal sheets, straightening, bending welding sheets and some parts of a tank. The transformer
tank is painted after washing and cleaning. It is colored silver or any light color because light
colors reflect sunlight and heat. In the core section the core is cut down and the core assembly
section the cutting core are arranged according to the measurement, core coil is wrapped in the
core coil assembly section, the coil is divided into two parts such as the LT coil and HT coil. The
wrapped coil is placed vertically inside the core. Then the bushing, thermometer, tap changer
installed on the upper side of the transformer. Before tank up wye- wye connection and delta –
delta connection is given in two sides of the coil after wrapping. Then the total set up is inserted
inside to the tank. After that the oil is filled to the transformer tank. There are different types of
tests they do before the final supply to the consumer like short circuit test, open circuit test,
vector group test, transformer ratio test etc.

vi
 Acknowledgement

At first, I am grateful to the Almighty Allah for giving me the capability to complete the internship
work perfectly. I am also grateful for the valuable guidance and encouragement of my supervisor,
Md Aziz Ul Huq, Professor, Department of Electrical and Electronic Engineering of IUBAT –
International University of Business Agriculture and Technology. Persistently and convincingly
conveyed the spirit and excitement in research, which resulted my exploration on different avenues
of research. He deserves special mention for his outstanding and generous help in various aspects of
this report. I am also grateful to the Founder of IUBAT Prof. Dr. M Alimullah Miyan for creating
learning environment. Also grateful to our sir Engr Abul Bashar (Coordinator, Dept. of EEE) for for
giving this opportunity to fulfill the requirement of graduation. And I would like to thank to Mr.
Mijanur Rahman, Managing Director and Engr. MD. Amin Uddin, Instructor of Bachhar Engineering
Ltd. for giving the opportunity to carry on my practicum in his reputed organization. Also, I would
like to thank to all engineers and stuffs of Zirabo Ashulia, Savar for guiding properly Finally, I
would like to acknowledge with due respect to my family, friends, and well-wishers for their
valuable support and encouragement which have always been considered as source of living
inspiration to me.

7
 Table of Content

Contents
Letter of Transmittal ...................................................................................................................................... 3
Student’s Declaration ..................................................................................................................................... 5
Executive Summary ....................................................................................................................................... 6
Acknowledgement ......................................................................................................................................... 7

Chapter 2 ....................................................................................................................................... 11

Transformer................................................................................................................................... 11
2.1 Introduction ............................................................................................................................................ 11
2.2 Working Principle of Transformer ......................................................................................................... 12
2.3 Constructional Parts of Transformer ...................................................................................................... 13
2.3.1 Primary winding of transformer Magnetic flux ............................................................................... 13
2.3.2 Secondary winding of transformer .................................................................................................. 13
2.3.3 Magnetic Core of transformer ......................................................................................................... 13
2.4 Main Components of Transformer ......................................................................................................... 13
2.4.1 Core ................................................................................................................................................ 13
2.4.2 Windings ......................................................................................................................................... 17
2.4.4 Tubes for cooling ............................................................................................................................ 18
2.4.5 Tap Changer .................................................................................................................................... 19
2.4.6 Transformer Oil .............................................................................................................................. 19
2.4.7 Main Tank ....................................................................................................................................... 20
2.4.8 Buchholz relay ................................................................................................................................ 20
2.4.9 Insulating Materials ......................................................................................................................... 20
2.4.10 Bushing ......................................................................................................................................... 20
2.4.11 Radiators ....................................................................................................................................... 23
2.4.12 Insulating tape ............................................................................................................................... 23
2.4.13 Conservator Tank .......................................................................................................................... 23
2.4.14 Thermometer ................................................................................................................................. 25
2.4.15 Explosion Vent.............................................................................................................................. 25

Chapter 3 ....................................................................................................................................... 25

8
 Transformer Types ........................................................................................................................ 25
3.1 Different Types of transformer .............................................................................................................. 25
3.1.1 Core type transformer ..................................................................................................................... 25
3.1.2 Shell type transformer ..................................................................................................................... 25

Chapter 4 ....................................................................................................................................... 28

Transformer losses ........................................................................................................................ 28

4.1 Different types of losses of a transformer .............................................................................................. 28
4.1.1 Copper Loss .................................................................................................................................... 28
4.1.3 Hysteresis Loss ............................................................................................................................... 28
4.1.5 Dielectric Loss ................................................................................................................................ 28
4.2 Efficiency ............................................................................................................................................... 29
4.3 Delta-Delta Connection of Transformer ................................................................................................. 29
4.4 Wye- Wye Connection of a transformer ................................................................................................ 30
4.5 Three phase transformer connections ..................................................................................................... 31

Chapter 5 ....................................................................................................................................... 32

Design and Manufacturing Process of 100kVA ........................................................................... 32

5.1 100kVA Transformer Design ................................................................................................................. 32
5.1.1 Core Design of 100 kVA transformer ............................................................................................. 32
5.1.2 Core Design of 100 kVA transformer ............................................................................................. 33
5.1.4 Secondary coil current and wire size calculation of 100 kVA transformer. ..................................... 35
5.1.5 Coil Turns Calculations of 100 kVA transformer ........................................................................... 36
5.1.6 Tapping Calculation of 100 kVA transformer ................................................................................. 36
5.2.1 Fabrication of tanks ......................................................................................................................... 36
5.2.2 Core Cutting .................................................................................................................................... 37
5.2.3 Core Classes .................................................................................................................................... 38
5.2.4 Core Arranging ............................................................................................................................... 39
5.2.5 Core Coil Assembly ........................................................................................................................ 41
5.2.6 Painting ........................................................................................................................................... 43
5.2.7 Tank up ........................................................................................................................................... 43
5.2.8 Oil filling......................................................................................................................................... 44

Chapter 6 ....................................................................................................................................... 45

Testing of Transformer ................................................................................................................. 45

6.1 Transformer Test .................................................................................................................................... 45
9
 6.1.1 Transformer Ratio Test ................................................................................................................... 46
6.1.2 Transformer short circuit test .......................................................................................................... 47
6.1.3 No load test or open circuit test ....................................................................................................... 48
6.1.4 Meggar test of a transformer. .......................................................................................................... 49
6.1.5 Dielectric Strength of Oil Test ........................................................................................................ 49
6.2 Capacity calculation of transformer of 11 kV range ............................................................................... 50
6.3 Safety device of transformer .............................................................................................................. 50
6.3.1 WTI- Winding Temperature Indicator ............................................................................................ 50
6.3.2 OTI- Oil Temperature Indicator ...................................................................................................... 50
6.3.3 Pressure Release Bulb ..................................................................................................................... 50
6.3.4 Buchholz relay ................................................................................................................................ 50
6.3.5 MOG- Magnetic Oil Gauge ............................................................................................................. 50

Conclusion .................................................................................................................................... 51
7.1 Conclusion ............................................................................................................................................. 51
7.2 Limitation .............................................................................................................................................. 52

References ..................................................................................................................................... 53

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 Chapter 2

Transformer

2.1 Introduction

Transformer is a static device which consists of two or more stationary electric circuits interlinked by
a common magnetic circuit for the purpose of transferring electrical energy between them. The
transfer of energy from one circuit to another takes place without a change in frequency [1]. It is used
to increase or decrease voltage levels between circuits. A transformer is a static device consisting of
a winding, or two or more coupled windings, with different number of turns on a magnetic core, for
inducing mutual coupling between circuits. The alternating current magnetic field created in one
winding induces a current in the other in proportional to the number of turns.

Fig: 2.1: 100 kVA Transformers at Bachar Engineering Ltd.

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2.2 Working Principle of Transformer

The main principle of operation of a transformer is mutual inductance between two circuits which is
linked by a common magnetic flux. A basic transformer consists of two coils that are electrically
separate and inductive, but are magnetically linked through a path of reluctance. The working
principle of the transformer can be understood from the figure below. As shown above the electrical
transformer has primary and secondary windings. The core laminations are joined in the form of
strips in between the strips you can see that there are some narrow gaps right through the cross-
section of the core. These staggered joints are said to be ‘imbricated’. Both the coils have high
mutual inductance. A mutual electro-motive force is induced in the transformer from the alternating
flux that is set up in the laminated core, due to the coil that is connected to a source of alternating
voltage. Most of the alternating flux developed by this coil is linked with the other coil and thus
produces the mutual induced electro-motive force. The so produced electro-motive force can be
explained with the help of Faraday’s laws of Electromagnetic Induction as:
e=M*dI/dt
If the second coil circuit is closed, a current flows in it and thus electrical energy is transferred
magnetically from the first to the second coil [2]. The alternating current supply is given to the first
coil and hence it can be called as the primary winding. The energy is drawn out from the second coil
and thus can be called as the secondary winding.

Fig 2.2: Transformer Working Principle

12
The coil connected to the main supply is called the primary and the other coil connected to the load
circuit is called the secondary. Now the Winding connected to higher voltage is known as high
voltage winding while the winding connected to low voltage is known as low voltage winding. In
case of a step up transformer, the primary coil (winding) is the low voltage winding, the number of
turns of the windings of the secondary is more than that of the primary. It is vice versa for step down
transformer.
Faraday’s Laws [3] of Electromagnetic Induction a (second law) state that the magnitude of emf €
induced in the coil is equal to the rate of change of flux that linkage with the coil.

2.3 Constructional Parts of Transformer

Transformer has three main parts, which are:

2.3.1 Primary winding of transformer Magnetic flux – produces by the primary winding.
2.3.2 Secondary winding of transformer –The secondary winding called output winding. The flux,
produced by primary winding, passes through the core and will link with the secondary winding.
2.3.3 Magnetic Core of transformer – produced flux by the primary winding, that will pass through
this low reluctance path linked with secondary winding and create a closed Magnetic circuit.

2.4 Main Components of Transformer

1. Core 8. Buchholz relay
2. Windings 9. Bushing
3. Breather 10. Radiators
4. Tubes for cooling 11. Insulating tape
5. Tap Changer 12. Conservator Tank
6. Transformer Oil 13. Thermometer
7. Main Tank 14. Explosion Vent

2.4.1 Core

Core is a laminated steel or silicon sheet where coil are wound. In an electrical power transformer,
there are primary, secondary and may be tertiary windings. The performance of a transformer mainly
depends upon the flux linkages between these windings. For efficient flux linking between these

13
windings, one low reluctance magnetic path common to all windings should be provided in the
transformer. This low reluctance magnetic path in transformer is known as core of transformer.

Fig 2.3: Transformer core at Bachar Engineering Ltd.

Fig 2.4: Transformer Core Construction

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2.4.1.1 Core Construction

In core type transformer the core surrounds the windings whereas in the shell type transformer the
windings surround the core of the transformer. In core type transformer the lamination is cut in the
form of L shape whereas in the shell type transformer, the lamination is cut in E and L shape. Core
made of laminated sheets provides the magnetic circuit for the flow of flux linking the magnetic
circuits.

2.4.1.2 Influence diameter of core

Then, cross-sectional area of the core,

15
 𝜋𝐷2 D = Diameter
𝐴= … … … … . (2)
4 F = Frequency

Now, Voltage per turn, E is proportional to D2

𝐸 = 4.44𝜙𝑚𝑓 = 4.44𝐴𝐵𝑚𝑓………..(3) Bm= Flux density

A= Area
Where Bm is the maximum flux density of the
core. D= Diameter
∅m= Flux
4.44 𝜋𝐷2𝐵𝑚𝑓
= … … … … … … . . (4) E= Emf
4
Here, f= frequency

Therefore voltage per turn is increased with increase in diameter of transformer core. Again if
voltage across the winding of transformer is V. Then V = E * N, where N is the number of turns
in winding. If V is constant, E is inversely proportional to N. And hence, D2 is inversely
proportional to N. So, diameter of the core is increased, the number of turns in the transformer
winding reduced. Reduction of number of turns, reduction in height of the core legs in-spite of
reduction of core legs height increased in core diameter, results increase in overall diameter of
magnetic core of transformer. This increased steel weight ultimately leads to increased core
losses in transformer.
2.4.1.3 Core Lamination
There are four types of core lamination
1. E-I lamination 3. U-I lamination
2. E-E lamination 4. L-L lamination

Fig 2.5: Transformer Laminations

16
2.4.2 Windings

A completed coil assembly with taps is often called a winding. Coil Winding is the Process of
making an electromagnetic coil. Coil winding basically consists of winding Wire (usually
copper or aluminum) around a core. The whole process from beginning to end product is
generally referred to as Coil Winding. Various types of winding are done depending on the
client’s requirement. Both windings are electrically insulated from each other through insulation
material. There is also a proper distance between two windings for movement of oil. Oil acts as
a cooling agent. Because windings become hot with the flow of current in windings [4].

2.4.2.1 LT Coil

For 100 kVA LT wire is used size is (8x3) BRB wire. Four 8x3 size BRB wire is used for LT
coil. This LT copper wire is coated with insulation paper.

2.4.2.2 HT Coil

Fig: 2.6: LT coil and HT coil winding of transformer at Bachar Engineering Ltd

For 100kVA SWG – 16super enameled copper wire is used for HT or primary winding. For
transformer coil winding super enameled Copper Wire of BRB is used. In the shows super
enameled Copper wire bundle for Primary winding.

2.4.2.3 Construction of Winding

Winding form the electrical circuit of a transformer. Their construction ensures safety under
normal and faulty conditions. The windings must be electrically and mechanically strong to
withstand both over-voltages under transient surges, and mechanical stress during short circuit,
and not attain temperatures beyond the limit under rated and overloaded conditions. For core
type transformer, the windings are cylindrical and arranged concentrically. Circular coils offer
the greatest resistance to radial component of emf, as such shape which coil will tend to assume
17
under short Circuit stresses.

Fig 2.7: Winding Construction at Bachar Engineering Ltd.

2.4.3 Breather
The function of breather in transformer is to filter out the moisture from air. Breather consists of
silica gel which absorbs the moisture from air. When there is overloading on transformer, the
winding of transformer gets heated so the oil in main tank of transformer also get heated.

Fig 2.8: Breather Fig 2.9: Tubes for cooling

2.4.4 Tubes for cooling

Cooling tubes are used in transformer to increase that heat dissipation in transformer Heat is
produced in transformer due to losses (copper and iron loss). in case of high power rating
18
transformer normal plain surface is not enough to dissipate the heat so tubes r used to dissipate
the heat. Heat dissipation is not proportional to diameter of tubes because of screened surface.

2.4.5 Tap Changer

The purpose of a tap changer is to regulate the output voltage of a transformer. It does this by
altering the number of turns in one winding and thereby changing the turn’s ratio of the
transformer. There are two types of transformer tap changers: an onload tap changer (OLTC)
and a reenergized tap changer (DETC)

Fig 2.10: Tap Changer

2.4.5.1 Types of tap changer
There are two types of tap changer
1. Off load tap changer
Transformer Off-Load Tap Changer. Taps are connections to the, usually high-voltage winding
of a transformer which enables changes to the turns ratio to be made in order to make changes to
the secondary voltage to compensate, where necessary, to a fall in terminal voltage below the
regulatory allowance.
2. On load tap changer
On Load Tap Changer. On load or Off-load tap changer is installed at the HV side of the
transformer. By tap changing, the primary turns are increased or decreased. When the tap
position is increased, the some of the primary turns get shorted and the flux in the core
increases.

2.4.6 Transformer Oil

Transformer oil is mineral based oil that is commonly used in transformers for its chemical
properties and dielectric strength. This oil in your transformer acts as an insulator and a cooling

19
agent. Normally there are two types of transformer oils are used and these are, Naphtha Based
Transformer Insulation Oil. Paraphin Based Transformer Insulation Oil.

2.4.7 Main Tank

It is a main part of Transformer. It is steel made box. Transformer core is placed inside this tank.
Windings and other helpful devices are placed inside this tank It is filled withinsulating oil
(mineral oil). It is coated internally and externally with color for safety point of view. Color
coating also provide protection in case of winding connection with tank accidentally.

2.4.8 Buchholz relay

Fig 2.12: Buchholz relay Fig 2.13: Insulating Materials

The Buchholz Relay is a protective device container housed over the connecting pipe from the
main tank to the conservator tank. It is used to sense the faults occurring inside the transformer.
It is a simple relay that operates by the gases emitted due to the decomposition of transformer oil
during internal faults. It helps in sensing and protecting the transformer from internal faults [5].

2.4.9 Insulating Materials

Insulating paper and cardboard are used in transformers to isolate primary and secondary
windings from each other and from the transformer core. Transformer oil is another insulating
material [6].

2.4.10 Bushing
A bushing is an insulated device that allows an electrical conductor to pass safely through a
grounded conducting barrier such as the case of transformer or circuit breaker. Bushings are
typically made from porcelain; though other insulating materials are also possible, generally
used. The bushings used for transformers having voltages above 36 kV are either oil filled or
capacitor type. The oil filled bushing consists of a hollow two-part porcelain cylinder with a
conductor, usually a cylinder, passing through its axis. The space between the conductor and the
inner surface of the porcelain is filled with oil. The oil is contained separately from the oil in the
transformer tank.

20
Fig 2.13: Transformer Main Tank

21
Fig 2.14: Bushing Fig 2.15: Radiators
22
2.4.11 Radiators
Radiator is a bank of hollow pipe line which is used to transfer the thermal energy from one
medium to another for the purpose of cooling. Some Bank are used at the power transformer for
cooling the transformer oil as well as reduces the winding temperature under loading condition.

2.4.12 Insulating tape

Fig 2.16: Insulating tape

It serves as electrical insulation to withstand the high voltages present inside the inside the
transformer. Second, it functions as a heat transfer medium to dissipate heat generated within
the transformer windings. Thus, the oil must maintain good electrical properties while resisting
thermal degradation and oxidization.

2.4.13 Conservator Tank

This is a cylindrical tank mounted on supporting structure on the roof the transformer main tank.
It is a small tank which used in high power transformers. It is connected above the main tank of
transformer. It has cylindrical shape. Main tank and conservator tank connected to each other
through a pipe. Buchholz relay is used between conservator tank and main tank in transformers
having capacity more than one MVA. Conservator tank [7].The main function of conservator
tank of transformer is to provide adequate space for expansion of oil inside the transformer.

23
Fig 2.17: Conservator Tank

Fig 2.18:Thermometer

24
2.4.14 Thermometer
Transformer Winding Temperature Thermometer. These devices are supposed to indicate hottest
spot in the winding based on the manufacturer’s heat run tests. Winding temperature
thermometers work the same as the top oil thermometer, except that the bulb is in a separate
thermometer well near the top of tank.

2.4.15 Explosion Vent

Fig: 2.19 Explosion Vent

Explosion vent is used to expel 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.

Chapter 3

Transformer Types
3.1 Different Types of transformer
Transformers can be classified on different basis, like types of construction, types of cooling etc.
On the basis of construction, transformers can be classified into two types as;

3.1.1 Core type transformer

A 'core type' transformer core is one in which the primary windings and secondary windings are
placed around each of the limbs, as opposed to a 'shell type' core, in which the two windings are
placed across the center core.

3.1.2 Shell type transformer

The shell type transformer is a simple rectangular form and the core surrounds the considerable
portion of the windings which is shown in fig. Both the primary & secondary windings are
placed in the one limb. And the coils are wound in from of multi-layer disc type. (A)On the
basis of their purpose

25
3.1.1.1 Step up transformer: (Voltage increases)
A transformer that increases the voltage from primary to secondary (more secondary winding
than primary winding turns is called a step-up transformer. Conversely, a transformer designed
to do just the opposite is called a step-down transformer.

3.1.1.2 Step down transformer: (Voltage decreases)

In a step-down transformer is one who secondary windings is fewer than the primary windings.
In o the words, the transformer’s secondary voltage is less than the primary voltage. So, the
transformer is designed to convert high-voltage, low-current power into a low-voltage, high
current power and it is mainly used in domestic consumption. (B) On the basis of type of supply.

3.1.1.3 Single phase transformer

A single phase transformer unified time phase. The ratio of primary (input) windings to
secondary (output) windings determines the change in current.

3.1.1.4 Three phase transformer

A three-phase transformer is made of three sets of primary and secondary windings, each set
wound around one leg of an iron core assembly. Three phase transformer core has three sets of
windings. Those sets of primary and secondary windings will be connected in either Δ or Y
configurations to form a complete unit. (C)On the basis of their use

3.1.1.5 Power transformer:

The Power transformer is a one kind of transformer that is used to transfer electrical energy in
any part of the electrical or electronic circuit between the generator and the distribution primary
circuits. These transformers are used in distribution systems to interface step up and step down
voltages. Used in Transmission network high rating.

3.1.1.6 Distribution transformer:

A distribution transformer or service 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. Used in distribution network comparatively
lower rating than that of power transformers. (D) On the basis on measurement

3.1.1.7 Instrument transformer:

Instrument transformer is an electrical device used to transform current as well as voltage level.
The most common use of instrument transformer is to safely isolate the secondary winding
when the primary has high voltage and high current supply so that the measuring instrument,
energy meters or relays which are connected to the secondary side of the transformer will not
get damaged.[8]

26
3.1.1.8 Current transformer (CT)
A current transformer is a device that is used for the transformation of current from a higher
value into a proportionate current to a lower value. It transforms the high voltage current into the
low voltage current due to which the heavy current flows through the transmission lines is safe.

Fig 3.1: Current Transformer Fig 3.2: Potential Transformer

3.1.1.9 Potential transformer (PT)

The potential transformer may be defined as an instrument transformer used for the
transformation of voltage from a higher value to the lower value. This transformer step down the
voltage to a safe limit value which can be easily measured by the ordinary low voltage
instrument like a voltmeter, wattmeter and watt-hour meters, etc. E) On the basis of cooling
employed
1. Oil-filled self-cooled type
2. Oil-filled water cooled type
3. Air blast type (air cooled)

27
 Chapter 4
Transformer losses

4.1 Different types of losses of a transformer

Since an electrical transformer has no rotating parts, it has no mechanical losses. This
contributes to its high operating efficiency of over 90%. However, like any electrical device, a
transformer does have losses. These losses appear in the form of heat and produce an increase in
temperature and a drop in efficiency. Losses can be classified into two categories: copper losses
and core losses.

4.1.1 Copper Loss

This loss is caused by the resistance of the copper wire in the primary and secondary windings.
A transformer winding can consist of hundreds of turns of fine copper wire, resulting in a
relatively-high resistance value. As current flows through this resistance, some power is
dissipated in the form of heat. Copper losses are minimized by employing large diameter
conductors to reduce the resistance per unit length of the wires. Copper losses are generally
about twice as great as core losses in most transformers.
4.1.2 Eddy Current Losses
Eddy currents are caused by the alternating current inducing a current in the core of the
transformer. The eddy current losses are kept to a minimum though the use of laminated cores.
Eddy currents increase with frequency; they are directly proportional to the square of the AC
frequency.

4.1.3 Hysteresis Loss

A rather esoteric form of loss, called hysteresis loss, occurs in all ferromagnetic transformer
cores, but especially in laminated iron. Hysteresis is the tendency for a core material to act
"sluggish" in accepting a fluctuating magnetic field. Air cores essentially never exhibit this type
of loss. In fact, air has lowest overall loss of any known transformer core material. Laminated
cores exhibit high hysss loss above the AF range, so they don't work well above a few kilohertz.
4.1.4 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.

4.1.5 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 effected
28
 4.2 Efficiency
𝑂𝑢𝑡𝑝𝑢𝑡 𝑤𝑎𝑡𝑡𝑠
%Efficiency= ∗ 100
𝐼𝑛𝑝𝑢𝑡 𝑤𝑎𝑡𝑡𝑠
𝑁𝑜 𝐿𝑜𝑎𝑑−𝐹𝑢𝑙𝑙 𝐿𝑜𝑎𝑑
% Voltage Regulation= ∗ 100
𝐹𝑢𝑙𝑙 𝑙𝑜𝑎𝑑

4.3 Delta-Delta Connection of Transformer

A Delta Delta is a 3-phase connection without a neutral you're going the same voltage on the
primary to the same voltage of the secondary but it's used for high current applications like
stated in this article.

Fig 4.1: Delta-Delta Connection of transformer

29
4.4 Wye- Wye Connection of a transformer

Fig 4.2: Wye-Wye Connection of Transformer

30
A delta-wye transformer is a type of three-phase electric power transformer design that employs
delta-connected windings on its primary and wye/star connected windings on its secondary. A
neutral wire can be provided on wye output side. An equivalent term is delta-star transformer.

4.5 Three phase transformer connections

A three-phase transformer is made of three sets of primary and secondary windings, each set
wound around one leg of an iron core assembly. Three phase transformer core has three sets of
windings. Those sets of primary and secondary windings will be connected in either Δ or Y
configurations to form a complete unit

Fig 4.3: Three phase transformer connections

31
 Chapter 5
Design and Manufacturing Process of 100kVA

5.1 100kVA Transformer Design

Fig 5.1: 100kVA Transformer Design

Fig 5.2: Core Design

5.1.1 Core Design of 100 kVA transformer

Fig 5.3: Core Design of 100 KVA

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Transformer

Stacked core are assembled with T-joint 60° mitered overlap corner joints are shown in Figure.
And in case of 200 kVA transformer Yokes are joined at an angle of 45 degree to utilize the
magnetic flux directional characteristics of steel strip.

5.1.2 Core Design of 100 kVA transformer

Table 5. 1: 100kVA (11/0.415kV) Core Design at Bachar Engineering Limited

A Core

SL L2 b L1 Stack Weight(KG)
NO
1 280 120 520 60 22.03
2 280 115 510 27 9.48
3 280 110 500 23 7.48
4 280 105 490 18 5.58
5 280 100 480 15 4.39
6 280 90 460 24 6.23
7 280 80 440 19 4.23
8 280 70 420 15 2.89
9 280 60 400 12 1.95
10 280 50 380 10 1.26
11 280 40 360 8 0.77
12 280 30 340 4 0.42
66.71

B core

SL L2 b L1 Stack Weight(KG)

NO
1 280 120 400 30 9.36
2 280 115 395 13.63 4.05
3 280 110 390 11.40 3.21
4 280 105 385 9.03 2.41
5 280 100 380 7.55 1.91
6 280 90 370 12.22 2.73
7 280 80 360 9.59 1.88
8 280 70 350 7.71 1.30
9 280 60 340 6.23 0.89
10 280 50 330 5.01 0.58
11 280 40 320 3.94 0.36
12 280 30 310 2.97 0.20

28.89

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 C Core

SL L2 b L1 Stack Weight(KG)
N
O
1 113 120 585 60 22.32
2 118 115 580 27 9.78
3 123 110 575 23 7.87
4 128 105 570 18 5.98
5 133 100 565 15 4.80
6 143 90 555 24 7.07
7 153 80 545 19 4.99
8 163 70 535 15 3.55
9 173 60 525 12 2.49
10 173 60 535 10 2.05
11 173 60 545 8 1.64
12 173 60 555 6 1.27

73.83
Total 169.43

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5.1.3 Primary coil current and wire size calculation 100 kVA transformer.

Primary side has delta connection system , we know for

delta connection E=line=E-phase=11kV and I-line=√3 ×
I – phase Power= E-Line × I line × √3 Or,I-line= 100
kVA/(11kv× √3)

Or,I-line=5.24/√3 amp

Or,I-line= 3.02 amp

5.1.4 Secondary coil current and wire size calculation of 100 kVA transformer.

We Know,
For star connection
E-line=E-phase*√3 =415 v and I-line =I-phase =?

Or,I-line= 100 kVA/(415× √3)

Or, I-line=I-phase= 130 amp

35
5.1.5 Coil Turns Calculations of 100 kVA transformer

Now Primary Coil Turns= Np/Ns

=(√3 ×Vp)/Vs
=(√3 × Vp× Ns)
or ,Np =(√3 ×11000×58)/415
or ,Np=2662.76 turns

5.1.6 Tapping Calculation of 100 kVA transformer

Tapping Ratio 2.5%

Tapping turns=2662.76*2.5%=59.91

Table 5.2Tapping Calculation of 100 kVA transformer

No of Turns Tapping
0 First
65 2nd

130 3rd
659 4th

5.2.1 Fabrication of tanks

Fabrication refers to preparation of the body of a transformer. This section includes cutting metal
sheets, straightening, bending welding sheets and some parts of a tank.

36
 Fig 5.5 Fabrication of tanks

Fig 5.6 Fabrication of tanks

5.2.2 Core Cutting

The material of these transformers are silicon steel. From a plain and large sheet, the pieces of
sheets are cut according to the measurement. Each core has a measurement. They are kept

37
separately according to the type.

Fig 5.7: Core Cutting

5.2.3 Core Classes

Fig 5.7: Core Classes

38
 Core A Core B Core C
Fig 5.8: Core classes
There are three types of core are used these are given in fig: Core A, Core B, Core C. The
measurement of core B depends on measurement A and is decorated according to core B.

5.2.4 Core Arranging

The core is arranged symmetrically and core is placed on top of another and thus all the cores are
arranged at a specific number.

39
40
 Fig 5.9: Core Arranging

5.2.5 Core Coil Assembly

There are two types of coil these are LT coil and HT coil. These coil are wrapped using an coil
wrapping machine. The secondary turn’s number of these coils depend on the primary turns. For
Primary and secondary there are specific numbers of turns. After wrapping the coil they are
placed inside the arranged core. Core is built with Cold Rolled Grain Oriented Silicon Steel, low
loss silicon steel lamination.

41
Fig 5.10: Core Coil Assembly (1)

42
The Core is vertically placed with the footplate touching the ground. A at the top of the core is
removed and limbs of the core is tightly wrapped with the cotton tape.

5.2.6 Painting

Fig 5.12: Transformer Tank painting at Bachar Engineering ltd.

The transformer tank is painted after washing and cleaning. It is colored silver or any light color
because light colors reflect sunlight and heat.

5.2.7 Tank up

5.2.7.1 Preparation of the Tank

Before tank up wye- wye connection and delta –delta connection is given in two sides of the coil
after wrapping. Then Bushing tap changer and other necessary equipment’s are connected to it.
Then the total set up is inserted inside to the tank.

43
Fig 5.13: Preparation of Tank Up (1) Fig 5.14: Preparation of Tank Up (2)

The Core-coil assembly is then placed into the tank and properly locked up

5.2.8 Oil filling

Fig 5.15: Transformer Oil filling

After the tank up and installed the bushing, thermometer, tap changer on the upper side of the
transformer then the oil is filled to the transformer tank. Transformer oil is oil that is stable at
high temperatures and has excellent electrical insulating properties. It function is to insulate and
cool a transformer. Oil required for 100 KVA transformers In case of 100 KVA transformer
200+ liter oil is required.

44
 Chapter 6

Testing of Transformer

6.1 Transformer Test

In Bachar Engineering generally seven transformer tests are used before sending to consumers.
The tests which are performed in Bachar are,
1. Ratio Test
2. Vector GroupTest
3. No LoadTest
4. Full LoadTest
5. Magnetizing CurrentTest
6. Insulation resistance test
7. Dielectric Strength of Oil Test

45
6.1.1 Transformer Ratio Test

Fig 6.1: Transformer ratio test

This test is done after core coil assembly under in process test. The ratio of the HT & LT winding of
the transformer is measured by Automatic Transformer Ratio Tester (ATRT) . It gives the values of
the ratio for both the LT and HT windings To know the ratio of a transformer the ratio test is
required. On primary side the voltage was 415 v and the secondary side the voltage was 15 v. And
the transformer ratio was 26. 60v.
Table 6.1 Transformer ratio test result
Tap 1 Tap 2 Tap 3 Tap 4 Tap 5
Vab 15.14 15.51 15.92 16.38 16.77
Vbc 15.19 15.31 15.69 16.08 16.55
Vca 15.05 15.45 15.83 16.25 16.67

46
 6.1.2 Transformer short circuit test

Fig 6.3: Transformer Short circuit Test

The supply voltage required to circulate rated current through the transformer is usually very small
and is of the order of a few percent of the nominal voltage and this voltage is applied across primary.
The core losses are very small because applied voltage is only a few percentage of the nominal
voltage and hence can be neglected. Thus the wattmeter reading measures only the full load copper
loss. This test is designed to determine the winding resistance and leakage reactance. In this test, the
secondary is short circuited by a thick conductor and variable low voltage is applied to the primary
side.
Table 6.2 Transformer full load test result
Voltage on Short Circuit Watt Meter
HT Side (Volt) Current (A) Reading
Vab Vbc Vca Vav Ia Ib Ic IAV W1 W2
411 412 413 412 26.60 26.70 26.50 26.60 1.09 8.1

The supply voltage required to circulate rated current through the transformer is usually very small
and is of the order of a few percent of the nominal voltage and this voltage is applied across primary.
47
The core losses are very small because applied voltage is only a few percentage of the nominal
voltage and hence can be neglected. Thus the wattmeter reading measures only the full load copper
loss.

6.1.3 No load test or open circuit test

This test is conducted to determine the core losses (or iron losses). In this test, the rated voltage is
applied to the primary while the secondary of the transformer is left open-circuited. A wattmeter is
connected to the primary.

Fig 6.4: Transformer open circuit test

Table 6.3: Transformer open Circuit test result
Voltage on No Load Watt Meter
LT Side (Volt) Current (A) Reading
Vab Vbc Vca Vav Ia Ib Ic IAV W1 W2
417 416 419 417.33 8.81 8.08 8.51 8.44 1.50 2.60

An ammeter is connected in series with the primary winding. A voltmeter is optional since the
applied voltage is same as the voltmeter reading. The frequency of the applied voltage must be the
rated frequency of the transformer. If the applied voltage is normal voltage then normal flux will be
48
set up. Insulation resistance tests are made to determine insulation resistance from individual
windings to ground or between individual windings. Insulation resistance tests are commonly
measured directly in mega ohms or may be calculated.

6.1.4 Meggar test of a transformer.

Megger leads are connected to LV and HV bushing studs to measure Insulation Resistance IR value
in between the LV and HV windings. Megger leads are connected to HV bushing studs and
transformer tank earth point to measure Insulation Resistance IR value in between the HV windings
and earth. The recommended practice in measuring insulation resistance is to always ground the tank
(and the core). Short circuit each winding of the transformer at the bushing terminals. Resistance
measurements are then made between each winding and all other windings grounded. Insulation
resistance testing: HV – Earth and HV
Table.6.4.Megger Test Result
Megger test voltage Terminal-1 Terminal-2 Test result (KΩ)
1000v HT+ body Ground 1000 (KΩ)
1000v LT+ body Ground 1000 (KΩ)
1000v HT + LT + body DAR 1000 (Ω)

6.1.5 Dielectric Strength of Oil Test

The oil test is essential and in most countries even mandatory, since the dielectric oil deteriorates in
its isolating and cooling qualities due to ageing and pollution by dust particles or humidity.

Table 6.5 Dielectric Strength of Oil Test

Sphere Gap Standard Observed Remarks
Strength(KV) Strength(KV)
2.6 50 53 OK

49
 6.2 Capacity calculation of transformer of 11 kV range
1000 × 100
𝐻𝑇 = = 5.24 𝐴
11000 × √3
1000 × 100
𝐿𝑇 = = 139.12 𝐴
415 × √3

6.3 Safety device of transformer

6.3.1 WTI- Winding Temperature Indicator

The Winding Temperature Indicator, WTI is provided with a maximum temperature indicator. The
heating resistance is fed by a current transformer associated to the loaded winding of the transformer.
The increase in the temperature of the resistance is proportionate to that of the winding.

6.3.2 OTI- Oil Temperature Indicator

The (OTI) oil temperature indicator consists of a sensor bulb, capacity tube, and a dial thermometer,
the sensor bulb is fitted at the location of hottest oil. The sensor bulb and capacity tube are fitted with
evaporation liquid. The vapor pressure varies with temperature and is transmitted to a bourdon tube
inside the dial thermometer, which moves in accordance with the changes in pressure, which is
proportional to the temperature.

6.3.3 Pressure Release Bulb

The working principle of transformer pressure release device is very simple. If pressure arises inside
a transformer and exceeds a pre-set pressure limit, the pressure safety valve opens its valve clap,
which is held by a spring and releases the internal pressure until it declines.

6.3.4 Buchholz relay

It is a type of oil and gas actuated protection relay. It is used for the protection of a transformer from
the faults occurring inside the transformer, such as impulse breakdown of the insulating oil,
insulation failure of turns etc.

6.3.5 MOG- Magnetic Oil Gauge

MOG (magnetic oil gauge) of Transformer. The MOG (Magnetic Oil Gauge) is a device by which
we can supervise the level of liquid/oil inside the tank or conservator of power transformer and also
gives us an alert low oil level indication with making mercury switch.

50
 Chapter 7
Conclusion

7.1 Conclusion

This report discussed about the assembling of 100 kVA transformers. In this report chapter 1 is about
the organizational overview, Chapter 2 is about introduction of transformer and its working principle,
main components of transformer, Core, Core construction. Chapter 3 is about different types of
transformer, Chapter 4 is about different types of losses of transformer, transformer connections,
efficiency of transformer and Chapter 5 is about the assembling process, design of 100 KVA and
200KVA transformers in details. Chapter 5 includes core design, primary coil current and wire size
calculation; coil turns calculations, tapping connections, fabrication of tanks, core cutting, core
arranging, painting, and tank up, oil filling. Chapter 6 is about the testing of transformer in
experimentally and 7 concludes the report my mentioning the limitation of the company.

51
 7.2 Limitation

1. The company is far from Dhaka City and the road transportation system is somewhat good.

52
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