A Summer Training Report on

ROYAL ELECTRICALS

Duration of the Training: 16-05-2022 to 31-05-2022

Semester: 4th

Bachelor of Technology

In ELECTRICAL ENGINEERING

By

M&V Patel Department of Electrical Engineering

C.S. Patel Institute of Technology
Faculty of technology and engineering
Charotar University of science &technology, changa june 2022

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 Acknowledgement

The internship opportunity I had with ROYAL ELECTRICALS was a great chance for
learning and professional development therefore, I consider myself as a very lucky
individual as I was provided with an opportunity to be the part of it. I am also grateful
for having a chance to meet so many wonderful people and professionals who lead one
through internship period.
 
Bearing in mind previous I am using this opportunity to express my deepest gratitude
and special thanks to Mr. Pinakinbhai Patel (MD of Royal Electricals) who in spite of
being extraordinarily busy with duties took out time to hear guide and keep me on the
correct path and allowing me to carry out my project at their esteemed organization
and extending during the training.
 
I express my deepest thanks to Mr. Pravinbhai Parmar (Chief Engineer) And Mr.
Bhaveshbhai Parmar (Supervisor) for taking part in useful decision and giving
necessary advices and guidance and arranged all the facilities to make my internship
easier I choose this movement to acknowledge his contribution gratefully.
 
It is my radiant sentiment to place on record my best regards, deepest sense of
gratitude to Mr. Sanjaybhai & Mr. Dineshbhai for their careful precious guidance
which were extremely valuable for my study both theoretically and practically

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Patel Dhruv Kiritbhai
D21EE023

Table of Contents

LIST OF FIGURES 1

LIST OF TABLES 2

DESCRIPTION OF THE COMPANY 7

Chapter 1 – INTRODUCTION 8

1.1 what is transformer? 8

Chapter 2 – COUNSTRUCTION OF TRANSFORMERS 9

2.1 Components used in transformer 9

2.2 Core 12

2.3 Winding 14

Chapter 3 – TYPES OF TRANSFORMERS 19

3.1 Different types by usage 19

Chapter 4 TRANSFORMER COOLING 23

4.1 Different types of colling 23

Chapter 5 Commissioning & Maintenance 28

5.1 Different types of test performant 28

5.2 Maintenance Schedule 33

Bibliography 37

Outcome of Internship 38

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 List of Figures

Ch – 1 Introduction
1. Transformer
Ch – 2 Counstrution of transformer
1. Different types of componants
2. Shell type & Core type
3. Multi-Layer Helical Windings
4. Helical Windings or Spiral Windings
5. Disc Windings
6. Foil Windings
7. Cylindrical Windings
8. Cross- Over Windings
9. Aluminum Windings
Ch – 3 Types of transformers
1. Power transformer
2. Distribution Transformer
3. Autotransformer
4. Special Design transformer

Ch – 4 Transformer Cooling
1. Air Natural (AF) Cooling.
2. Oil Natural Air Natural (ONAN) Cooling.
3. Oil Natural Air Forced (ONAF) Cooling.
4. Oil Forced Air Forced (OFAF) Cooling.
5. Oil Forced Water Forced (OFWF) Cooling
Ch – 5 Commissioning & Maintenance
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 1. Short circuite
2. Open circuit
3. Oil Breakdown test

List of Tables

1 Maintenance Schedule 33

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 DESCRIPTION OF THE COMPANY

About The Company

Royal Transformers is a a segment of Royal Electricals, an Anand-based firm has
been a pioneer in transformer manufacturing and also been specifically a handy firm
that has had filter machines available on rental basis since its inception in 1987.
Royal electricals is certified by URS and UKAS

 
Basically, Royal electricals is owned by MR. Pinakinbhai A. Patel
 
Talking about the working of company they are global and integrated transformer
manufacturers in India selling wide range of products like power transformers,
distribution transformers, furnace transformers, dry type transformers, and service
repairing transformers, as per industry requirements. They also give custom solutions
to their clients on special requests.

They have contract of Repairing transformers of AMUL, MGVCL, Apar industries,

Atlanta Electricals.

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 Chapter 1: Introduction

1.1) What Is Transformer?

A transformer is a static (or stationary) piece of apparatus by means of which electric

power in one circuit is transformed into electric power of the same frequency in
another circuit. It can raise or lower the voltage in a circuit but with a corresponding
decrease or increase in current. The physical basis of a transformer is mutual
induction between two circuits linked by a common magnetic flux. In its simplest
form, it consists of two inductive coils which are electrically separated but
magnetically in Fig. The two coils possess high mutual inductance. If one coil is
connected to a source of alternating voltage, in alternating flux is set up in the
laminated core, most of which is linked with the other coil in which it produces
mutually induced e.m.f. (according to Faraday's Laws of Electromagnetic Induction
Maids. If the second call circuit is closed, a current flow in it and so electric energy is
transferred (entirely magnetically? from the first coil to the second coil. The first coil,
in which electric energy is fed from the ac supply mins, is called primary winding and
the other from which energy is drawn out, is called secondary winding In brief, a
transformer is a device that
1. transfers electric power from one circuit to another
2 does so without a change of frequency
3. it accomplishes this by electromagnetic induction and
4. where the two electric circuits are in mutual inductive influence of each other

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 Chapter 2: COUNSTRUCTION OF TRANSFORMERS

2.1) Components used in transformer

1) Conservator Tank
This is a cylindrical tank mounted on supporting
structure on the roof the transformer main tank. The
main function of conservator tank of transformer is
to provide adequate space for expansion of oil inside
the transformer.
When transformer is loaded and when ambient temperature rises, the volume of oil
inside transformer increases. A conservator tank of transformer provides adequate
space to this expanded transformer oil. It also acts as a reservoir for transformer
insulating oil.

2) Oil level Indicator

The oil level indicator displays if air bubbles have
remained in the transformer, if gas has been
generated because of an internal failure or if there
is a leakage at the transformer tank.

3) Thermometer
Transformer Oil Temperature Indicators - also known as
electromechanical thermometers or OTIs for short - are
essential devices on oil-filled transformers, providing
accurate temperature measurement of the oil.

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4) Breather
A breather is an accessory of liquid-immersed power
transformers attached to the conservator tank. They
serve as the breathing point of the transformer. The
breather contains silica gel crystals which have a
tremendous capacity of absorbing moisture.

5)Buchholz Relay

A Buchholz relay is a safety device mounted on

(some) oil-filled power transformers and
reactors, equipped with an external overhead oil
reservoir called a “conservator”. Buchholz relays
are used as a protective device, as they are
sensitive to the effects of dielectric failure that
can occur inside the equipment they protect.
Buchholz relays are a type of gas detection relay.

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The Buchholz relay working principle is very simple. Buchholz relay function is
based on a very simple mechanical phenomenon.
It is mechanically actuated. Whenever there will be a minor internal fault in the
transformer such as an insulation fault between turns, breakdown of core of the
transformer, core heating, the insulating transformer oil will be decomposed in
different hydrocarbon gases, CO2 and CO.
The gases produced due to the decomposition of transformer insulating oil will
accumulate in the upper part of the Buchholz container which causes a fall of the oil
level in it.

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2.2) Transformer Core
The transformer core provides a magnetic path to channel flux. The use of highly
permeable material (which describes the material’s ability to carry flux), as well as
better core construction techniques, helps provide a desirable, low reluctance flux
path and confine lines of flux to the core. The core is constructed of numerous thin
strips of grain-oriented silicone steel, called laminations, which are electrically
isolated (yet still magnetically coupled) from each other by thin coatings of insulating
material. This is important to reduce the no-load losses of the transformer. The core
is a source of heat in the transformer and as a core increase in size, cooling ducts
within the core may become necessary. Problems such as short-circuited core
laminations will result in increased losses and possibly overheating of the transformer
core.

There are two types of transformers according to core design.

1) Shell type
2) Core type

In that we have four designs E-I, E-E, L-L, L-U

1) Shell type transformer
In shell type of transformer each phase
has more than one magnetic circuit
surrounding the winding.

In that type of transformer

Length of winding is longer

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 And magnetic core length of winding is shorter which translates in to larger
percentage of impedance.

Shell type construction allows flow of zero sequence flux through the lateral
legs and tank heating is not a problem.

Windings are arranged in alternating high and low voltage coils in a sandwich
or disc fashion.

2) Core type transformer

In core type of
transformer each phase
has separate magnetic
circuit.

In that type of
transformer length of
winding is shorter and
magnetic core length of
winding is longer which translates in to lower percentage impedance.

For 3 phase 3 core units there is no path of zero sequence flux which causes
the flux to flow through the air gap and causes tank heating.

Low voltage winding is placed close to the core and high voltage winding on
the outside

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2.3) Transformer winding
Transformer winding includes different turns of copper coil bundles where
every bundle is connected to form a winding. Windings mainly depend on the
input-output supply otherwise on the range of voltage.
Transformer winding is available in two types like primary winding and
secondary winding.

Transformer winding operation is, that the primary winding gets electrical
energy from the source whereas secondary winding transmits electrical energy
to the load.
Transformer winding materials are aluminum and copper which are the most
frequently used conductors in transformer windings. The mechanical strength
and conductivity are high for copper whereas aluminum materials are less cost
and lightweight as compared to copper. Generally, copper windings are used
in large transformers whereas aluminum conductors are used for small size
and medium size transformers
There are two types of aluminum core.
CPC and Super Aluminum

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2.3.1) Transformer Winding Types
Transformer windings are available in different types like the following.
 Multi-Layer Helical Windings
 Helical Windings or Spiral Windings
 Disc Windings
 Foil Windings
 Cylindrical Windings
 Cross- Over Windings
 Disc & Continuous Disc Winding
 Aluminum Windings

Multi-Layer Helical Windings

These windings are mainly used for high voltage rating-
based transformers like 110 kV & above. These types of
windings comprise numerous cylindrical layers which
are wounded & connected in series. The external layers
of these transformer windings are made shorter as
compared to the inside layers for allocating the
capacitance consistently. These windings are mainly
used to enhance the transformer’s surge behavior.

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Helical Windings or Spiral Windings
Helical windings are known as spiral windings which are used for low voltage & high
capacity-based transformers, where the flow of current is higher & the turns of winding are
smaller. The transformer output changes from 160 to 1000 kilovolt-ampere & 0.23 to 15
Kilovolt.

Disc Windings
The designing of disc windings can be done by connecting several
conductor discs in series. Initially, a disc can be formed by winding
different insulated conductor turns & after that connected in series
to make disc winding. Every disc can be separated from the nearby
disc with spacers.
The main disparity between a disc & helical winding is that the
helical winding includes simply a single twist of parallel conductor
for each disc whereas the disc winding includes numerous turns for
each disc. Disc type windings are used in the above 25kV rated
transformer. Similar to helical, these windings are also robust mechanically.
Foil Windings

Foil windings are mainly designed with thin aluminum or copper

sheets where the thin insulated sheet is covered several times to
make multilayer spiral windings. This winding can be formed
either with a single or many sheets within a parallel wound on
the plane side. These are applicable in high capacity-based
transformers where the current ranges from 12 – 600 A.

Cylindrical Windings
These windings use low voltage up to 6.6 kV &
their current rating ranges from 10 – 600 A.
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These windings are frequently used in multi-layer forms. In these types of windings, we
utilize circular type conductors which are wounded on vertical strips to enhance cooling
conditions.
This arrangement will create oil ducts to help better cooling. These windings are applicable
where high voltage ratings are used up to 33 kV, 800 kVA & current ratings up to 80 A. For a
bare conductor, the highest diameter size used is 4 mm.
Cross over Windings
Cross-over windings are used in small transformers. These
windings are separated into several coils to decrease the
voltage among contiguous layers where these coils are
divided axially through 0.5 to 1 mm of distance. The
voltages between contiguous coils should not be above 800 –
1000 V.
The actual axial length of every coil is approximately 50
mm whereas the spacing in two coils is 6 mm to hold
insulating material blocks. The coil’s width ranges from
25mm to 50 mm. The strength of these windings is high as compared to cylindrical type
windings in normal conditions.

Disc & Continuous Disc Winding

This type of winding is normally used in high capacity-based transformers where these
windings include several discs or flat coils in a series or parallel configuration. The formation
of these coils can be done using rectangular strips which are spirally wounded within a radial
direction.
The conductors in these types of windings are single or multiple strips within a parallel
configuration that is wound on the level side. So this conductor’s formation will make the
construction very strong.
The discs in these windings are divided from each other with pressboard sectors where these
sectors are connected to vertical stripes.

Aluminum Windings
Aluminum windings are the
most predominant choice to use
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in different transformers in North America like dry type and low voltage. In most areas all
over the world, the copper winding is the main winding material but the main reason to choose
this aluminum winding is its initial cost is low.
Aluminum winding is more flexible as compared to copper so making it very easy. The
maximum resistivity of aluminum provides inherently fewer eddy losses within the windings.
This reduces the possibility of hot spots. Transformers with aluminum winding or copper
winding have the same losses & performance. Aluminum wound coils are bigger as compared
to copper coils.

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 Chapter 3 – TYPES OF TRANSFORMERS

 Power Transformers
A power transformer transfers electricity
between a generator and the distribution
primary circuits. It gets a little bit
confusing because many use the term
‘power transformer’ to encompass a
bunch of transformers, rather than a
specific design type. Likewise, some even
refer to large transmission transformers as
power transformers, to easily differentiate between distribution transformers.

Regardless of the exact definition, power transformers can have one of three jobs – step up
generator output voltage to the transmission system voltage level, step down transmission
voltages to safe levels for distribution, or step down voltage to the auxiliary power system
level in a generating station.

Power transformers can also fall into one of two class – class I or class II. Very original
naming system, I might add. Anyways, class I power transformers have high-voltage windings
of 69 kV and below, while class II power transformers have high-voltage windings between
115 kV and 765 kV.

Just to make things a tad more complicated, you can also categorize these by size – small,
medium, or large. Small power transformers fall under 69 kV, medium up to 230 kV, and
large power transformers are between 138-765 kV.

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  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. The
invention of a practical efficient
transformer made AC power distribution
feasible; a system using distribution transformers was demonstrated as early as 1882.

If mounted on a utility pole, they are called pole-mount transformers. If the distribution lines
are located at ground level or underground, distribution transformers are mounted on concrete
pads and locked in steel cases, thus known as distribution tap pad-mount transformers.

Distribution transformers normally have ratings less than 200 kVA, although some national
standards can allow for units up to 5000 kVA to be described as distribution transformers.
Since distribution transformers are energized for 24 hours a day (even when they don't carry
any load), reducing iron losses has an important role in their design. As they usually don't
operate at full load, they are designed to have maximum efficiency at lower loads. To have a
better efficiency, voltage regulation in these transformers should be kept to a minimum. Hence
they are designed to have small leakage reactance.

 Auto-transformer

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The primary and secondary windings of an Autotransformer are linked together both
electrically and magnetically reducing the cost over conventional transformers

When the primary current

IP is flowing through the
single winding in the
direction of the arrow as
shown, the secondary
current, IS, flows in the
opposite direction.
Therefore, in the portion of the winding that generates the secondary voltage, VS the current
flowing out of the winding is the difference of IP and IS.

The Autotransformer can also be constructed with more than one single tapping point. Auto-
transformers can be used to provide different voltage points along its winding or increase its
supply voltage with respect to its supply voltage VP as shown.

Advantages of using Auto Transformers

 For transformation ratio = 2, the size of the auto transformer would be approximately
50% of the corresponding size of two winding transformer. For transformation ratio
say 20 however the size would be 95 %. The saving in cost of the material is of course
not in the same proportion. The saving of cost is appreciable when the ratio of
transformer is low, that is lower than 2. Thus auto transformer is smaller in size and
cheaper.
 An auto transformer has higher efficiency than two winding transformer. This is
because of less ohmic loss and core loss due to reduction of transformer material.
 Auto transformer has better voltage regulation as voltage drop in resistance and
reactance of the single winding is less.

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Disadvantages of Using Auto Transformer
 Because of electrical conductivity of the primary and secondary windings the lower
voltage circuit is liable to be impressed upon by higher voltage. To avoid breakdown in
the lower voltage circuit, it becomes necessary to design the low voltage circuit to
withstand higher voltage.
 The leakage flux between the primary and secondary windings is small and hence the
impedance is low. This results into severer short circuit currents under fault conditions.
 The connections on primary and secondary sides have necessarily needs to be same,
except when using interconnected starring connections. This introduces complications due
to changing primary and secondary phase angle particularly in the case of delta/delta
connection.
 Because of common neutral in a star/star connected auto transformer it is not possible to
earth neutral of one side only. Both their sides should have their neutrality either earth or
isolated.
 It is more difficult to maintain the electromagnetic balance of the winding when voltage
adjustment tappings are provided. It should be known that the provision of tapping on an
auto transformer increases considerably the frame size of the transformer. If the range of
tapping is very large, the advantages gained in initial cost is lost to a great event.

 Special Design Transformer

Special Design Transformers makes it possible to provide uninterrupted single-phase power

supply during load shedding time and 3 phase power supply for the remaining number of
hours. That is 24 X 7 hours power supply to agricultural and household usage for the rural
population

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 Chapter 4: TRANSFORMER COOLING

Cooling of a transformer is the process of dissipation of heat developed in the transformer to the
surroundings. The losses occurring in the transformer are converted into heat which increases the
temperature of the windings and the core. Therefore, cooling is done to dissipate the heat
generated in the transformer.
There are different types of cooling is available in transformers as below:
 Air Natural (AF) Cooling.
 Oil Natural Air Natural (ONAN) Cooling.
 Oil Natural Air Forced (ONAF) Cooling.
 Oil Forced Air Forced (OFAF) Cooling.
 Oil Forced Water Forced (OFWF) Cooling
Those are the main types of transformer cooling.

 Air Natural (AF) Cooling.

In a dry type transformer the air is only the medium to take away the heat generated in the
transformer. The fans are used to force the cooling of the winding and core of the transformer.
This type of cooling is called AN (Air Natural).
Air Natural cooling system is used in many transformers. This method is used in low-capacity
transformers. It has cooled medium air and its circulation is natural.

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  Oil Natural Air Natural (ONAN) Cooling.

The heat produced in the winding and core is transferred to the transformer oil by conduction. The
heated oil, being lighter, moves up on the transformer tank and the cool oil takes the place of hot
oil. Thus, by convection process the oil circulates from bottom to top of the tank. The heat is then
taken away by the ambient temperature. The efficiency of the cooling system depends on the
temperature of ambient temperature and surface area of the transformer. To increase the surface
area of the transformer, radiator is fitted on the transformer tank. ONAN method of cooling is best
suited for small rating oil filled transformer up to 5 MVA.

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  Oil Natural Air Forced (ONAF) Cooling.

ONAF method is used for the cooling of the transformer of rating up to 60 Mega volts ampere. As
discussed above that in ONAN method, the dissipation of heat is taking place by the convection
process in which air is naturally circulated to cool down, but in this type, the forced air is used for
the purpose of cooling the transformer.

The cooling of oil will be faster if the area of the tank of the transformer is increased finally,
which result in the increase in heat dissipation level. As the fans and blowers are installed, a high
velocity of air is forcefully applied to the radiator and cooling towers which will help in cooling
oil more quickly and efficiently.

Its cost is higher as compared to another process where the circulation of oil and air is done
naturally because a fan and blowers are attached as extra cooling equipment, in this method.

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  Oil Forced Air Forced (OFAF) Cooling.

As the name itself says that both the oil and the air are applied by force for cooling of a
transformer. The Heat Exchanger is installed through which hot oil is circulated with the help
of a pump. Air is forced to pass on the heat exchanger with the help of high-speed fans.

This method is similar to ONAN, as when there is low load on the transformer the cooling is
done by a simple ONAN method. However, as soon as the load is increased, the generated
heat will also be more and therefore the sensor gives an alarm that the dissipation of heat has
exceeded the safe value and as a result, the fans and pumps are switched on automatically.
Thus, the cooling takes place by OFAF method.

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  Oil Forced Water Forced (OFWF) Cooling

A heat exchanger is installed through which both oil and water are passed with the help of a
pump. The level and pressure of the oil are always kept higher than that of water so that if any
leakage occurs in the system the oil mixes with the water, but water does not get mixed up
with the oil.

This type of method is suitable for large capacity of the transformer having rating as several
hundred MVA or where banks of transformers are installed. Mainly this type of cooling is
done for the transformer installed at the hydropower plant.

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 Chapter 5: Commissioning
5.1) Commissioning
The type tests of a transformer are performed at the manufacturer’s premises to prove the design
expectations and consumer’s specifications. The type tests are performed in a prototype unit, not
in all manufactured units and these tests confirm the basic and main design criteria of the
transformer.
We perform different types of test on transformer as below:
 Ratio test
 Vector group check test
 Insulation resistant test
 Short circuit test
 Open circuit test
 Double voltage Double frequency test
 Oil Breakdown test
Pre Commissioning Test
Prior to energizing the transformer, several pre-commissioning test are done. The objective of
these tests is confirm that the transformer has not suffered damage during transit and also to check
any inadvertent slips in the factory tests, or supply.

 Ratio Test
Ratio between all the three corresponding H.V. & L.V. phases is to be measured on all taps. It is
desirable to do this test by a Ratio-meter. But if it is not available, a simple test of measuring
voltages can also serve the purpose. Referring to R&D plate, fine out which terminals of H.V. &
L.V. correspond to one phase e.g. for a vector Group of Dyn-11, H.V. Terminals 1U, 1V, & L.V.
terminals 2U, 2N correspond to U phase. Apply single phase, 415 V or 240 V, AC., 50 Hz to H.V.
side and measure voltage on the L.V. side. Measure these voltages on all taps and note them in
―Commissioning Report‖ Repeat for the other two phase. These observations should indicate a
consistent trend of variation in line with the details given in R&D Plates. Numerical values should
approximately check with the voltage ratio

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  Vector Group Check Test
Connect terminals 1U, 2U together. Apply 3 phase, 415 V, 50 Hz. AC. To H.V. terminals 1U,
1V, 1W. Measure voltages between terminals 1V-2V, 1V-2W & 1W-2V, 1W-2W (or suitable
other voltages if required). Check that the measured Voltages confirm the relative position of
H.V. & L.V. vector group. For vector group Dyn-11. H. V. & L.V. vectors are shown
independently positioned for Dyn-11, For the condition 1U & 2U connected together, L.V.
Vectors are redrawn as shown. With this configuration, Voltages 1V-2V & 1V-2W will be equal
while 1W-2V will be greater than 1W-2W. The method can be extended to any other Vector
Group. Note the observations in the ―Commissioning Report.

 Measurement of Insulation Resistance

Measure Insulation Resistance (IR) between windings and between windings and earth with a
2500/1000V Megger, preferably motor driven otherwise hand-driven. Before measuring I.R.,
thoroughly clean all the bushings with clean cotton cloth, if required using Carbon Tetrachloride.
Also, there should be no external connections to the transformer terminals. Check and adjust, if
required, the infinity setting of the Megger. Lead wires from the Megger to the transformer should
run independently and be permanently clamped. They should not have any joints. It is known that
the I.R. reading continues to increase initially and for comparison purpose, reading continues to
increase initially and for comparison purpose, reading is to be taken at 1 minute of energizing. It
is also known that I.R. value is dependent on temperature. Hence temperature at the times of
measurement should be noted. Compare the I.R. values measured, with the Factory results
keeping in view the temperature at the time of measurement. Note the observations in
―commissioning Report‖. Also measure and note the I.R. values of the power Cable.

 Short-Circuit Test
A low voltage of around 5-10% is applied to that HV side with the help of a variac (i.e. a variable
ratio auto transformer). We short-circuit the LV side of the transformer. Now with the help of
variac applied voltage is slowly increased until the wattmeter, and an ammeter gives reading equal
to the rated current of the HV side.

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After reaching the rated current of the HV side, we record all the three instrument readings
(Voltmeter, Ammeter and Watt-meter readings). The ammeter reading gives the primary
equivalent of full load current IL. As the voltage applied for full load current in a short circuit test
on the transformer is quite small compared to the rated primary voltage of the transformer, the
core losses in the transformer can be taken as negligible here.
the short-circuit test of a transformer is used to determine copper losses in the transformer at full
load. It is also used to obtain the parameters to approximate the equivalent circuit of a transformer
 Open circuit test
The voltage at rated frequency is applied to that LV side with the help of a variac of variable ratio
auto transformer.

The HV side of the transformer is kept open.

Now with the help of variac, applied voltage
gets slowly increased until the voltmeter gives
reading equal to the rated voltage of the LV
side. After reaching rated LV side voltage, we
record all the three instruments reading.
The ammeter reading gives the no load current
Ie. As no load current Ie is quite small compared to rated current of the transformer, the voltage
drops due to this current that can be taken as negligible.
The open circuit test on transformer is used to determine core losses in transformer and
parameters of the shunt branch of the equivalent circuit of the transformer.

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  Double voltage Double frequency test
The induced over voltage test is also called as double voltage double frequency test. This test is
carried out at a test frequency which is twice the rated frequency at which the equipment is
supposed to operate during its life time, so that the core does not saturate. The transformer is fed
with double voltage to test the withstand capability for higher voltages due to lightning surges and
faults in transformer
As per IEC specifications, test should be carried out by applying double the rated voltage (usually
LV side is preferred) at double the rated freque ncy to the transformer for 1 minute, one winding
open circuited(usually HV preferred)

There is no restriction on frequency, as it can be more than double the rated frequency but it
should not be less than double the rated. Time period depends upon test frequency as follows

Time(s)=120x(rated frequency)/(test frequency)

so for 22KV/433V 50Hz transfomer

Test voltage will be 866V

Test frequency will be 100Hz

Time will be 1 min

Test will be successful if all three windings will show equal currents.

 Oil Breakdown test

Transformer oil testing consists of measuring breakdown voltage and other physical and chemical
properties of samples of the oil, either in a laboratory or using portable test equipment on-site.

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The transformer oil (insulation oil) of voltage transformers and current transformers fulfills the
purpose of insulating as well as cooling. Thus, the dielectric quality of transformer oil is essential
to secure operation of a transformer.[3][4]

As transformer oil deteriorates through aging and moisture ingress, transformer oil should,
depending on economics, transformer duty and other factors, be tested periodically.[5] Electric
utility companies have a vested interest in periodic oil testing because transformers represent a
large proportion of their total assets. Through such testing, transformers' life can be substantially
increased, thus delaying new investment of replacement transformer assets.

Breakdown voltage testing procedure

 The transformer oil is filled in the vessel of the testing device. Two standard-compliant
test electrodes with a typical clearance of 2.5 mm are surrounded by the dielectric oil.
 A test voltage is applied to the electrodes and is continuously increased up to the
breakdown voltage with a constant, standard-compliant slew rate of e.g. 2 kV/s.
 At a certain voltage level breakdown occurs in an electric arc, leading to a collapse of
the test voltage.
 An instant after ignition of the arc, the test voltage is switched off automatically by the
testing device. Ultra fast switch off is highly desirable, as the carbonization due to the
electric arc must be limited to keep the additional pollution as low as possible.
 The transformer oil testing device measures and reports the root mean square value of
the breakdown voltage.

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  After the transformer oil test is completed, the insulation oil is stirred automatically
and the test sequence is performed repeatedly: typically 5 repetitions, depending on the
standard.
 As a result the breakdown voltage is calculated as mean value of the individual
measurements.

5.2) Maintenance Schedule

Recommended maintenance schedule is given below. However, depending on the local situation
and importance of transformer, frequency may be increased.
SI Inspection Items to be Inspection Action required
NO. Frequency Inspected Notes inspection shows
Unsatisfactory
conditions.
1 HOURLY Ambient - -

Winding Temp Check that temp. Shut down the

transformer and
investigate
Oil Temperature Rise is reasonable If either is persistently
higher than normal
Load (amperes) - Control load.
2 DAILY Oil level in Transformer Check against transformer If low, top up with dry
on load tap changer oil temperature. oil, examine
transformer for leaks.
Explosion vent - Replace if cracked or
broken.
dehydrating breather Check color of the active If silica gel is pink
agent and that opening is change by spare charge.
not clogged. The old charge may be
reactivated for further
use.
3 Quarterly Bushing Examine for cracks and Clean or replace as

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 dirt deposits. necessary

Oil in Transformer And Check for dielectric Take suitable action to

tap changer. strength and water restore quality of oil.
content.
On load tap changer Check oil. -
driving mechanism.
On load tap changer Check all circuits -
automatic control independently. Check step
by step operation
including limit switches
Ventilators (In case of Check that air passages -
indoor transformers) are free.
4 YEARLY Oil in transformer and Check the acidity Filter or replace.
sludge.
Insulation Resistance Compare with values at Process if required.
the time of
commissioning
Gasketed joints. - Tighten the bolts evenly
to avoid uneven
pressure.
Cable Boxes. Check for sealing Replace gaskets, if
arrangements for filling leaking.
holes. Examine
compound for cracks.
Check moisture
condensate If any in air
filled boxes.
Relay alarms, their Examine real and alarm Clean the components
circuits, etc. contacts and their or replace contacts and
operation fuses, etc. fuse, if necessary
Check relay accuracy, etc. change the setting if
necessary.
Temperature Indicator Pockets holding Oil to be replenished, if
thermometers should be required.
checked.
Dial type Oil Gauge Check pointer for Adjust if required.
freedom of movement.
Paint work Should be inspected. Any painting or
retouching should be
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 done if necessary.
Earth Resistance - Take suitable action if
earth resistance is high.
Surge diverter and gap Examine for cracks and Clean or replace
dirt deposits.
5 2 Non conservator Internal inspection above Filter oil regardless of
transformers care condition.
YEARS
Coil Conservator Internal Inspection Should be thoroughly
cleaned.
Buchholz reply Mechanical inspection Adjust floats, switches
etc. as required.
6 5 Transformer up to 3 MVA Overall inspection Wash by hosing down
including lifting of core with clean dry oil.
YEARS
and coils. Tighten coil clamping
arrangements and other
bolts, nuts, if loose.
7 7 to Transformer above Overall inspection Wash by hosing down
3MVA including lifting of core with clean dry oil.
10 Years
and coils. Tighten coil clamping
arrangements and other
bolts, nuts, if loose.

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 Bibliography

 Poly phase transformer and AC rotating electrical machines

By R.P. Ajwalia
 Electrical technology volume II
By B.L. Thereja & A.K. Theraja
 http://in.royaltransformers.com/
 https://en.wikipedia.org/wiki/Transformer


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 Outcome of Internship

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

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