Transformer Manufacturing Company Report

Chapter-1
INTRODUCTION OF TRANSFORMERS
1.1 Basics of Transformers
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:
By appropriate selection of the ratio of turns, a transformer thus enables an alternating

current (AC) voltage to be "stepped up" by making Ns greater than Np, or "stepped down"
by making Ns less than Np. The windings are coils wound around a ferromagnetic
core, air-core transformers being a notable exception.
Transformers range in size from a thumbnail-sized coupling transformer hidden inside a
stage microphone to huge units weighing hundreds of tons used to interconnect portions
of power grids. All operate on the same basic principles, although the range of designs is
wide. While new technologies have eliminated the need for transformers in some
electronic circuits, transformers are still found in nearly all electronic devices designed
for household ("mains") voltage. Transformers are essential for high-voltage electric
power transmission, which makes long-distance transmission economically practical.
1.2 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
Department of Electrical Engineering SKIT M&G, Jaipur Page 1

the current flowing in the coil. Figure 1 shown below explains the above principle.
Figure 1.1: Relationship between current, magnetic field strength and flux
A transformer is a static piece of apparatus used for transferring power from one circuit
to another at a different voltage, but without change in frequency. It can raise or lower the
voltage with a corresponding decrease or increase of current.
Δ𝐵 Δ𝐵
Vp = -Np A Vs = -Ns A
Δt Δt
Vs Ns
= Np
Vp
Figure 1.2: Transformer schematic

When a changing voltage is applied to the primary winding, the back e.m.fs generated by
the primary is given by Faraday’s law.
Δ𝐵
EMF = Vp = -Np A --- (1)
Δt
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 also given by Faraday’s law
Δ𝐵
Vs = -Ns A --- (2)
Δt
The rate of change of flux is the same as that in primary winding. Dividing equation (2)
by (1) gives
Vs Ns
=
Vp Np
In Figure 2, the primary and secondary coils are shown on separate legs of the magnetic
circuit so that we can easily understand how the transformer works. Actually, half of the
primary and secondary coils are wound on each of the two legs, with sufficient insulation
between the two coils and the core to properly insulate the windings from one another and
the core. A transformer wound, such as in Figure 2, will operate at a greatly reduced
effectiveness due to the magnetic leakage. Magnetic leakage is the part of the
magnetic flux that passes through either one of the coils, but not through both. The larger
the distance between the primary and secondary windings, the longer the magnetic circuit
and the greater the leakage. The following figure shows actual construction of a single
phase transformer.
Figure 1.3: Transformer construction

The voltage developed by transformer action is given by
E = 4.44×f×N×Bmax×Acore
Where, E = rated coil voltage (volts),
f = operating frequency (hertz),
N = number of turns in the winding,
Bmax = maximum flux density in the core (tesla), and
Acore = cross-sectional area of the core material in Sq.
meters.
In addition to the voltage equation, a power equation expressing the volt-ampere rating in
terms of the other input parameters is also used in transformer design. Specifically, the
form of the equation is
VA = 4.44×f×N×Bmax×Acore×J×Acond
Where, N, Bmax, Acore and f are as defined above, J is the current density (A/ sq. mm),
and Acond is the coil cross-sectional area (mm2) in the core window; of the conducting
material for primary winding. J depends upon heat dissipation and cooling.
1.3 TYPES OF TRANSFORMER
A. Oil filled Transformers

 Power Transformers
 Mobile Transformers
 Distribution Transformers
 Furnace Transformers
a. Induction Furnace Duty
b. Arc Furnace Duty
 Motor Starting Transformers
 Neutral Grounding Transformers
 Rectifier Duty Transformers
 Testing Transformer
B. Encapsulated & VPI transformers
 Air Cooled Transformers
 Cast Resin Transformers
 Boosters & Voltage Regulators
C. Reactors
 Air Core Reactors
 Gap Core Reactors

CHAPTER-2
MANUFACTURING PROCESS OF TRANSFORMER
 Winding Construction
 Core Assembly
 Core & Winding(Coil) Assembly (CCA)
 Tapping &Tap Changer
 Drying Process
 Tank Construction
 Tanking & Final Fitting
 Fittings & Accessories
 Painting
 Oil Filling & Filtration
 Testing
2.1 Winding Construction:-
Conducting material is used in the windings of the transformer. Usually the windings are
in concentrically to minimize the flux leakages. There are two types of windings. The
coils are wound on the limbs and are insulated from each other in the basic transformer
the two windings wound on the two different limbs. Due to this leakage flux increases
which affects the transformer efficiency or performance so it should be necessary that
the windings should be very close to each other to increase the mutual inductance.
Such cylindrical coils are used in core type transformers and sandwich coils are very
commonly used in shell type transformer here each high voltage winding lies between
two low voltage windings such subdivisions of windings into small portions reduce 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.

2.1.1 TYPES OF WINDING
1) Helical Winding
2) Layer Winding
3) Disc Winding
4) Interleaved Winding
Helical Winding Layer Winding
Disc Winding Interleaved Winding
Fig. 2.1 Types of Winding
Helical/Layer windings are most suitable for low voltage windings of large power
transformers to mitigate high current design requirement. For High voltage windings the
disc coils with excellent mechanical strength are used to take the stresses due to voltage
level. Special interleaved or shielded construction offers most uniform voltage

distribution despite system transient. Specialized disc winding and inter-leaved disc
windings are used having very high series of capacitance giving a very good impulse
voltage performance.
Transpositions are made in multiple conductor windings, to ensure uniform current
distribution, minimize circulating currents, decrease eddy current loss and improve the
lamination factor.
Transformer windings are made almost exclusively of copper, or to be precise, high-
conductivity copper. Copper has made possible much of the electrical industry as we
know it today because, in addition to its excellent mechanical properties, it has the
highest conductivity of the commercial metals. Its value in transformers is particularly
significant because of the benefits which result from the saving of space and the
minimizing of load losses.
The load loss of a transformer is that proportion of the losses generated by the flow of
load current and which varies as the square of the load current.
This falls into three categories:
 Resistive loss within the winding conductors and leads.
 Eddy current loss in the winding conductors.
 Eddy current loss in the tanks and structural steelwork.
Resistive loss can be lessened by reducing the number of winding turns, by increasing the
cross-sectional area of the turn conductor, or by a combination of both. Reducing the
number of turns requires an increase in 8m, i.e. an increase in the core cross-section,
which increases the iron weight and iron loss. So load loss can be traded against iron loss
and vice versa. Increased frame size requires reduced winding length to compensate and
thus retain the same impedance, although as already explained there will be a reduction in
the number of turns (which was the object of the exercise) by way of partial
compensation. Reduction of the winding axial length means that the core leg length is
reduced, which also offsets the increase in core weight resulting from the increased frame
size to some extent. There is thus a band of one or two frame sizes for which loss
variation is not too great, so that optimum frame size can be chosen to satisfy other
factors, such as ratio of fixed to load losses or transport height.
The paths of eddy currents in winding conductors are complex. The effect of leakage flux
within the transformer windings results in the presence of radial and axial flux changes at
any given point in space and any moment in time.These induce voltages which cause
currents to flow at right angles to the changing fluxes. The magnitude of these currents
can be reduced by increasing the resistance of the path through which they flow, and this
can be effected by reducing the total cross-sectional area of the winding conductor or by
subdividing this conductor into a large number of strands insulated from each other. (In
the same way as laminating the core steel reduces eddy current losses in the core). The

former alternative increases the overall winding resistance and thereby the resistive
losses. Conversely, if the overall conductor cross-section is increased with the object of
reducing resistive losses, one of the results is to increase the eddy current losses. This can
only be offset by a reduction in strand cross-section and an increase in the total number of
strands. It is costly to wind a large number of conductors in parallel and so a
manufacturer will wish to limit the total number of strands in parallel. Also, the extra
insulation resulting from the increased number of strands results in a poorer winding
space factor.
Compact size is important for any item of electrical plant. In transformer windings this is
particularly so. The size of the windings is the determining factor in the size of the
transformer. As explained above the windings must have a sufficiently large cross-section
to limit the load losses to an acceptable level, not only because of the cost of these losses
to the user but also because the heat generated must be removed by the provision of
cooling ducts. If the losses are increased more space must be provided for ducts. This
leads to yet larger windings and thus a larger core is needed to enclose them. Increasing
the size of the core increases the no-load loss but, along with the increase in the size of
the windings, also means that a very much larger tank is required which, in turn, results
in an increased oil quantity and so the whole process escalates. Conversely, any savings
in the size of windings are repaid many times over by reductions in the size of the
transformer and resultant further savings elsewhere. As the material which most
economically meets the above criteria and which is universally commercially available,
high-conductivity copper is the automatic choice for transformer windings.
Fig 2.2 Winding Construction

2.2 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.
The step lap or Mitred joints at the core corners ensure a stream line magnetic flux path.
The core limb are held with resin bonded glass bands to eliminate limb bolts. Yokes are
clamped by solid mild steel plates with yoke stud ensuring high rigidity for withstanding
mechanical socks during transportation & Short Circuits. The leg core in a which hard
wooden bars are inserted, are tighten with synthetic resin impregnated fibre glass tape.
The transformer core is closed magnetic circuit built up of thin laminations of electrical
sheet steel. It is intended to concentrate the main magnetic flux linking with the winding
and consists of limbs which carry the windings and yokes which close the magnetic
circuit. The core laminations are insulated from one another by a film of heat-resistant
coating or varnish, or by a combination of both. There may be forms of magnetic circuit:
the shell type and the core type.
A magnetic circuit of the shell types is branched: there are two yokes per limb, which
encircle the limbs on both sides. As the magnetic flux leaves a limbs, it branches off into
two parts, therefore, in shell-type transformers, the cross-sectional area of the limbs is
twice that of the yokes. The limbs and yokes are rectangular in section, which
necessitates the use of rectangular disk windings. Because of the insufficient strength of
such windings in the event of short circuits, complications in assembly and also
somewhat greater mass of the shell-type magnetic circuits as compared with the core
types circuits using cylindrical windings, the shell type in the Soviet Union is employed
only for single-phase transformers in household appliances and for some special-purpose
transformers.

The core-type magnetic circuits of butt-joint or interleaved construction are used in
power transformers. In such circuits, two or three vertical circuits are bridged over by two
horizontal yokes the top and the bottom one so that a closed magnetic circuit is
formed.The core limbs and yokes are built up of separate laminations of electrical sheet
steel 0.35 or 0.5 mm think.
The core is built horizontally by stacking laminations, usually two or three per lay, on a
jig or stillage. The lay-down sequence must take account of the need to alternate the
lengths of plates to provide the necessary overlaps at the mitred corners as shown in
shows a large core being built in the manufacturer’s works. The clamping frames for top
and bottom yokes will be incorporated into the stillage but this must also provide support
and rigidity for the limbs until the core has been lifted into the vertical position for the
fitting of the windings. Without clamping bolts the limbs have little rigidity until the
windings have been fitted so the stillage must incorporate means of providing this. The
windings when assembled onto the limbs will not only provide this rigidity, in some
designs the hard synthetic resin-bonded paper (s.r.b.p.) tube onto which the inner winding
is wound provides the clamping for the leg laminations. With this form of construction
the leg is clamped with temporary steel bands which are stripped away progressively as
the winding is lowered onto the leg at the assembly stage. Fitting of the windings requires
that the top yoke be removed and the question can be asked as to why it is necessary to
build it in place initially. The answer is that some manufacturers have tried the process of
core building without the top yokes and have found that the disadvantages outweigh the
saving in time and cost of assembly. If the finished core is to have the lowest possible
loss then the joints between limbs and yokes must be fitted within very close tolerances.
Building the core to the accuracy necessary to achieve this without the top yoke in place
is very difficult. Once the windings have been fitted the top yoke can be replaced,
suitably interlaced into the projecting ends of the leg laminations, followed by the top
core frames. Once these have been fitted, together with any tie bars linking top and
bottom yokes, axial clamping can be applied to the windings to compress them to their
correct length.
The reason we laminate the iron cores in transformers is because we want to limit what
are called eddy currents. Transformers are basically two coils of wire wrapped around a
core of iron. They work by induction. Induction occurs when current flows in one
conductor (or one set of windings in the transformer) and the magnetic field that forms
around that conductor (that set of windings) sweeps the other conductor (the other set of
windings) and induces a voltage. In order to increase the effectiveness of the transformer,
we need to improve the way the magnetic fields are coupled from one set of windings to
the other set. Iron conducts magnetic lines of force well, so we use that to help conduct
the magnetic lines of force from coil A to coil B. Problem is, iron is also a conductor, and

it's being swept by the magnetic field as well. If we didn't use laminations, the iron core
would provide a place for the magnetic lines to produce (induce) current, and that current
flowing in the core would heat the core up really fast and waste energy.
Before concluding the description of core construction, mention should be made of the
subject of core earthing. Any conducting metal parts of a transformer, unless solidly
bonded to earth, will acquire a potential in operation which depends on their location
relative to the electric field within which they lie. In theory, the designer could insulate
them from earthed metal but, in practice, it is easier and more convenient to bond them to
earth. However, in adopting this alternative, there are two important requirements:
1. The bonding must ensure good electrical contact and remain secure throughout
the transformer life.
2. No conducting loops must be formed, otherwise circulating currents will result,
creating increased losses and/or localised overheating.
Metalwork which becomes inadequately bonded, possibly due to shrinkage or vibration,

creates arcing which will cause breakdown of insulation and oil and will produce gases
which may lead to Buchholz relay operation, where fitted, or cause confusion of routine
gas-in-oil monitoring results by masking other more serious internal faults, and can thus
be very troublesome in service.
The core and its framework represent the largest bulk of metalwork requiring to be
bonded to earth. On large, important transformers, connections to core and frames can be
individually brought outside the tank via 3.3 kV bushings and then connected to earth
externally. This enables the earth connection to be readily accessed at the time of initial
installation on site and during subsequent maintenance without lowering the oil level for
removal of inspection covers so that core insulation resistance checks can be carried out.
In order to comply with the above requirement to avoid circulating currents, the core and
frames will need to be effectively insulated from the tank and from each other,
nevertheless it is necessary for the core to be very positively located within the tank
particularly so as to avoid movement and possible damage during transport. It is usual to
incorporate location brackets within the base of the tank in order to meet this
requirement. Because of the large weight of the core and windings these locating devices
and the insulation between them and the core and frames will need to be physically very
substantial, although the relevant test voltage may be modest.

Fig. 2.3 Core Assembly

2.3 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.
Fig. 2.4 Core & Winding(Coil) Assembly
2.4 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.
Fig. 2.5 Tap Changer
2.5 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 @ 90°C &
respective vacuum cycle at rated interval to improve Insulation resistance and remove
ingress of moisture in insulation material.
Drying of grain involves exposing grain to air with low relative humidity (RH) which
will lead to evaporation of the moisture in the grain and then the moisture’s removal
away from the grain. Since drying practices can have a big impact on grain or seed
quality, it is important to understand some fundamentals of grain drying.
2.5.1 Moisture removal

In paddy grain, moisture is present at two places: at the surface of the grain, ‘surface
moisture’, and inside the kernel, ‘internal moisture’. Surface moisture will readily

evaporate when grain is exposed to hot air. Internal moisture evaporates much slower
because it first has to move from the kernel to the outside surface. As a result, surface
moisture and internal moisture evaporate at a different rate. This difference results in a
different ‘drying rates’ for different period of drying. The drying rate is defined as the
rate at which grain moisture content declines during the drying process. It is normally
expressed in percent moisture removed per hour [%/hr]. Typical drying rates of rice
dryers are in the 0.5%/hr to 1%/hr range.
A drying curve, as illustrated in the figure below, shows how the grain moisture content
(MC) and grain temperature change over time. As can be seen in the chart, the drying
rate is not constant but changes over time. The temperature of the grain equally changes
over time.
Fig. 2.6 Theoretical drying curves with different drying periods.
2.5.1.1 Drying periods and implications optimal drying
There are three different drying periods which will occur consecutively in time:
I.Preheating period (drying rate is almost 0):

When wet grain is exposed to hot air, initially only a very slight change in MC is
observed. This happens because all the heat provided in the drying air is used to heat
up the grain to the drying temperature.
II.Constant-rate period (drying rate is constant in time):

Once the grain is at the drying temperature, water starts to evaporate from the surface

of the grain. During this period, all the heat from the drying air is used to evaporate
surface moisture and the amount of moisture removed from the grain is constant in
time. It is therefore called the constant-rate period. During this period, grain
temperature is constant as well.
III.Falling-rate period (drying rate declines over time):

As time passes, it takes more time for internal moisture to appear at the surface, and
evaporation of water is no longer constant in time. As a result, drying rate will
decline, and some of the heat from the drying air will heat up the grain. For paddy
grain, the falling-rate period typically occurs at around 18% grain moisture content.
By using the 18% MC and the drying curve characteristics as a guideline, a few
recommendations can be made in regard to grain drying procedures. These guidelines can
be used regardless whether grain is dried in the sun or by using artificial grain dryers.
2.5.2 Drying rate and temperature
Above 18% MC the grain drying rate can be increased (that is, drying will occur faster)
by providing a higher temperature or more drying air without major changes in grain
temperature. Below 18%MC increase in drying air temperature will not increase the
drying rate but will increase grain temperatures and potentially damage the grain.
Therefore, higher drying air temperatures can be used to dry grain quickly down to 18%
MC (to remove "surface moisture") but lower temperatures should be used to remove
internal moisture from the grain.For seed purposes, drying air temperatures should never
exceed 43ºC, regardless of the MC, to avoid overheating of the grain which kills the
germ. Exposing paddy to 60ºC for one hour can reduce the seed germination rate from
95% to 30%. Two hours at 60ºC will reduce the germination rate to 5%.
2.5.3 Uniform drying
During the drying process there is always variability in MC of individual grains.

Especially in fixed-bed dryers the grains at the air inlet dry faster than at the air outlet
resulting in a moisture gradient in the grain bulk at the end of the drying process. For
production of good quality grain or seed, this variability should be kept as low as
possible. Frequent stirring in sun drying, grain turning in fixed bed dryers or circulation
in re-circulating batch dryers will improve uniformity of drying, minimize the re-wetting
of dried grains and thus maintain grain quality.

2.5.4 Tempering
When the drying of grain is temporarily stopped the moisture within the grain equalizes
due to diffusion. When drying is restarted, the drying rate becomes higher compared to
continuous drying. The process of stopping intermittently is called tempering. In addition
during tempering the moisture differences between grains equalize. Tempering therefore
also ensures that moisture gradients in the grain bulk that develop during drying in certain
dryer types are minimized.To maintain grain quality, including a tempering period is
recommended to allow for redistribution of internal moisture in the grain. In modern re-
circulating grain dryers, grain is not dried continuously but goes through a cycle of
drying followed by tempering. This improves drying rates, grain quality and reduces
energy costs.
2.6 Tank Construction
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.
2.7 Tanking & 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. Pressed Core & Coil Assembly is put in to the tank with proper locating &
locking arrangements which is of prime importance to achieve high resistivity against
transient damages, vibrations during service and Forces develop during fault occurrence.
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.
Fig. 2.7 Final Fitting
2.8 Fitting & Accessories:-
2.8.1 Rating & Terminal Marking Plate

The transformer is supplied with rating and terminal marking plate made out of non-
corrosive metal. The plate contains information concerning the rating, voltage ratio,
weights, oil quantity, vector group, etc. The plate also includes unit Sr. no. and year of
manufacturing.
Fig. 2.8 Rating & Terminal Marking Plate

2.8.2 Tap Changing Arrangement
2.8.2.1 Off-circuit Switch

The transformer is normally fitted with an off-circuit tap changing switch to obtain
required voltage ratio. It can be hand-operated by a switch handle mounted either or tank
cover or on the tank side. The locking device is fitted to the handle to lock in any tap
position. The switch mechanism is such that it can be locked only when it is located in its
proper position and not in any intermediate position.
The transformer must be isolated from all time the live lines, before operating the switch.
Operating the switch when transformer is energized, will damage the switch contacts due
to severe arcing between the contacts and many damage transformer winding.
When switch handle is provided on the side wall, it is necessary that switch handle
assembly is dismantled before undertaking.
2.8.2.2 Off circuit ratio changing links

Some times links are provided inside the transformer tank to obtain required voltage
ratio. Links are required to be loosened and fixed in new required position as given in R
& D plate. Links are accessible from the inspection cover. In case of conservator units,
oil level has to be lowered below the inspection cover before unbolting inspection cover.
2.8.2.3 On load tap changer

The on load tap changer is an optional fitting. The on load tap changers are provided with
local manual control, local electrical control and remote electrical control. The automatic
voltage regulation can also be provided as an optional fittings.
The tappings are located on high voltage winding.
Fig. 2.9 On-Load Tap Changer

2.8.3 Earthing terminals
The core laminations assembly is connected to core clamping frame which is in turn
connected to the tank. Two earthing terminals are provided on the transformer tank. The
earthing terminals should be connected to the earthing.
2.8.4 Lifting Lugs

Two or four lifting lugs of adequate capacity are provided on a tank sides/top cover to lift
fully assembled transformer filled with oil.
All lugs are designed for simultaneous use and must be used according. Two or four
lifting lugs are provided for undertaking the core and windings of larger capacity
transformer.
All heavy fittings are also provided with individuals lifting lugs.
2.8.5 Valves
Every transformer is provided with drain cum filter valve at bottom of tank, and filter
valve at top of the tank. Valves are fitted with plugs/blanking plates to stop oil coming
out.
Mainly two types of valves are provided.
1. Wheel valves.
2. Butterfly valves.
The wheel valves are used either with female screw threads or with flanges. These are of
gun metal/cast iron type.
Generally, one isolating valve also known as shut off valves is provided for transformer
up to 2000KVA between conservator and buchholz relay.
The butterfly type cast steel valves with the machined flanges are used at points of
connection between tank and detachable radiators.
Fig. 2.10 Valves

2.8.6 Bushings
2.8.6.1 Oil Communicating Type

Transformers windings are connected to the external circuit through terminal bushings.
The bushings are installed on the cover or on side walls of the transformer tank. The
lower end of the bushing protrudes in to the tank and at both their ends are provided with
suitable fasteners to connect the line leads in side the transformer and external conductors
out side it.
The shape and size of the bushings depends on the voltage class, type of current.
Electrical performance of these bushings conforms to I.S 2099 and I.S 7421. dimensional
details and associated parts generally conform to I.S 3 up to 36 KV class. Bushings of
1000 volts are of two piece construction with out arcing horns, whereas all other bushings
is possible without disturbing the active part. For bushings of two piece construction,
tank cover is required to be removed for necessary access to the inner (lower) end of the
bushings. These bushings are not detached at the time of transportation.
2.8.6.2 Condenser Bushings

Generally, condenser bushings are used for 72.5KV and above. These bushings contain
their own oil and are sealed to retain the same. Whenever these bushings are mounted on
bushings pockets or raised truncated portions, air vent pips are provided for carrying
away air or gases from these pockets to Buchholz relay during service typical assembly.
These bushings are detached from the transformers and dispatched separately. They are
packed as per manufacturer’s instructions. The draw through type lead is coiled and kept
temporarily below the bushing blanking plate. The equipment required for mounting the
bushings are
(1) Rope slings.
(2) Flexible steel wire approx 2mm in diameter, of suitable length.
2.8.7 Cable Boxes

Cable boxes are designed for receiving & protecting cables ends. Insulating paper is
most hygroscopic & all paper insulated cable ends must be protected by suitable
insulating compound. These cable boxes are provided with brass wiping glands &
designed with clearances insides the box suitables for compound filling. The cable box in
such case must be filled with compound as marked as indicated in the drawling.
Cable boxes of PVC are XLPE cables are designed with air clearances and hence these
boxes are not required to be filled with compound.
Cable boxes of 3.6 KV & above are provided with detachable gland plates. Earthing
terminals are also provided on these cable boxes for earthing the amounting of
individual cable when cable boxes are provided with disconnecting chambers they
permit removal of transformers for servicing without disturbing cable terminations.

2.8.8 Bus-duct\trunkings
Some users prefer connections to load by means of bus-duct. Bus-duct is supplied by
some other agency However, we provide suitable flanges/ trunkings around transformer
bushings for receiving the bus-duct.
The level of the bus-duct flanges from ground/rail level is indicated in the
general.Arrangement drawings of the transformer. the complete details of bus-duct flange
is furnished by us giving dimensional details for the matching flanges, bolt spacing,
bushing terminal details, etc
2.9 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.
2.10 Oil Filling & Filtration
All the Transformers are supplied with first filling of oil conforming to IS 335. Before
filling, oil is heated, filtered and vacuum treated in filter machine to remove any foreign
particles, moisture and air.
Fig. 2.11 Oil Filling

2.11 Testing
Before dispatch, each and every transformer is subjected to all routine tests as specified
by IS/IEC/BS/ANSI standards.
2.11.1 TYPES OF TESTING

1. Partial discharge test
2. Noise level measurement
3. Temperature rise test
4. Sweep Frequency Response Analyzer (SFRA) Test

2.11.1.1 Partial discharge test
Partial Discharges (PD) in the high voltage insulation are local breakdowns of the
insulation which does not result in a complete failure of insulation. Hence, the discharges
are called partial. The change in the PD value is measured in unit apparent charge pC.
Current transformers and Potential transformer are very important equipments of any
power system for metering and protection. Failure of these equipments will cause
 Short circuit fault in the system,

 Damage to other surrounding equipment / switchgear and
 Cause Non-availability of the system.
2.11.1.1.1 Reasons for PD in Instrument Transformers

The instrument transformers when manufactured in factory, due to its manufacturing
process workmanship, some voids are present. These voids over a period of time start
increasing in size due to overvoltages in system or ageing. When a voltage is applied to
the object the gaseous particles start getting ionizing. At a particular stage the void size
increases causing the apparent charge (pC) value to increase and finally cause failure of
the instrument transformer. The failure or increase in PD value can also be due to
moisture or contamination on the external surface of the equipment which may cause
tracking with respect to earth.
2.11.1.1.2 Test Description and Set-up

For this test rated phase to neutral voltage is applied across the object. A coupling
capacitor (having low inductance) is connected across the test object which converts the
input currents to low output voltage. The output of this coupling capacitor is fed to the
PD measuring instrument which gives the PD value in Pico Coulomb and also indicates
the discharges on the sinusoidal waveform. The most important requirement for this test
is a PD free power source transformer.
2.11.1.1.3 Limiting values and Testing schedule

As per Indian Standard (IS) 11322 – the limiting value of PD in Cast resin instrument
transformer is < 50 pC
Manufacturers limit this value to less than 20 pC before dispatch from their factory.
PD testing of instrument transformers should be carried out
 Just before commissioning to have the base foot print values at site.
 Once in every 2 years to trend the ageing or increase in the pC value and
 Depending upon the pC value measured over a period of six or twelve
months.

2.11.1.2 Noise level measurement
The test procedure is in accordance with IEC Standard 60076-10.At first, the background
noise level shall be measured. Then, the transformer shall be powered at rated voltage
and frequency under no-load conditions (with the tap-changer selected on the principal
tapping), in order to carry out transformer noise level measurements.They shall be
performed in several points located around the transformer, placed at a distance of 0,3 m
from the machine unless, due to safety reasons or following agreement between supplier
and purchaser, the distance is increased to 1m. Measuring positions shall be spaced at a
distance of at most 1 metre one from another; anyway, a minimum of 6 positions is
required. The measurements shall be carried out at half the equipment height, if this does
not exceed 2,5m; otherwise, they shall be performed at 1/3 and 2/3 of the component
height.
After performing transformer sound level measurement, the machine is de-energised and
background noise level is measured again; At the end, the final transformer sound level
shall result by applying a correction by taking into account the lower background noise
level. In case there is a high difference between the transformer and background noise
level (>8 dB) no correction shall be applied.
Fig. 2.12 CONNECTIONN SCHEME

2.11.1.3 Temperature rise test
The test is for verifying whether the temperature rise limits of the windings , as agreed at
the time of the enquiry, are respected. The test can be carried out by means of two
different methods:
 Simulated loading method (in accordance with. IEC 60726 p.21.1.3)

 The method used is defined at the time of the enquiry.
The average temperature rise shall be determined by means of the variation of winding
resistance. The core temperature rise shall be determined by use of a thermometer. All the
carries at rated conditions shall be performed in accordance with IEC 60726.
2.11.1.3.1 Simulated loading method

Temperature rise test is made by utilising the rises obtained on two tests, one with no-
load loss only, and one with load-loss only.
The no-load test, at the rated voltage and rated frequency, is continued until steady state
conditions are obtained; individual winding temperature rises are then calculated by
measurement of hot windings resistance, that shall be carried out as shortly as possible
after is connection. The short-circuit run with rated current flowing in one winding and
the other winding short-circuited, is started immediately following the no-load run, and
continued until steady state conditions are obtained; individual windings temperature
rises are then calculated as above mentioned. The total winding temperature rise of each
winding, with rated current in the winding and normal exitation of the core, shall be
calculated in accordance with IEC Standards 60726.
2.11.1.4 Sweep Frequency Response Analyzer (SFRA) Test

The SFRA test is non-intrusive (non-destructive) test. SFRA is an OFF line testing and it
can be carried out for any voltage rating of Power Transformer, Generator Transformer
and Distribution Transformer. The measurement of SFRA can be a part of regular
transformer maintenance. The SFR Analyzer identifies the following abnormalities in the
transformer before they lead to failure,
a. Core movement
b. Winding deformation and displacement
c. Faulty Core ground
d. Partial winding collapse
e. Hoop buckling
f. Broken or loosened clamping structures
g. Shorted turns and open winding
The Technique of SFRA is a major advance in transformer condition monitoring analysis.

This is a proven technique for making accurate and repeatable measurements.

The test can be carried out,
a) First to obtain initial signature (record) of the transformer Sweep
frequency response for future reference / comparison.
b) Periodical measurement as a maintenance check, once in two years.
c) Immediately after a major external Short Circuit, specially for faults
electrically closer to transformer.
d) Transportation or re-location of transformer.
e) Earthquakes

CHAPTER-3
INSTALLATION & COMMISSIONING
This section illustrated procedure for installation & Commissioning of our transformers.
A format of “Commissioning Report” is included at the end of this section. Results of
various pre commissioning tests as well as well as confirmation of check point are to be
recorded in this report. This Report then would saver as a handy record for future
reference.
3.1 Installation
3.1.1 Location
The transformer should be kept in a well ventilated place, free from excessive dust,
corrosive fumes etc. Adequate ventilation is necessary for tank radiators so that they can
dissipate heat. There should be clear space of about 1.25 m on all sides of the
transformers if it is enclosed in a room.
3.1.2 Foundation
Foundation should be firm, horizontal and dry. Where rollers are fitted, suitable rails
should be provided.
3.1.3 Provision for oil draining

Necessary provisions for oil draining, in the event of a fire, should be made by way of oil
soak pits. Fire separation walls should also be provided when necessary.
3.1.4 Assembly of Dismantled components

Various components dismantled for transportation should be duly assembled.
3.1.5 Main Tank

Keep the main tank in its permanent position of operation. Lock the rollers to prevent any
accidental movement on rails. Draw an oil sample from the botton of the tank and test it
for Break-Down-Voltage (BDV).
Note this value in “Commissioning Report”
3.1.6 Bushing
Clean the bushings and check that there are no hair-cracks or other damages. Test IR
value of each bushing with a 500V Megger. It should be 100 M ohms or greater. Note
details of Bushings in the “Commissioning Report.” Mount all the bushings as described
in 2.6. Ensure that the test tap cap is fully tightened, thus positively grounding the same.

Adjust the Arcing Horn Gaps in accordance with the Insulation Co-ordination Note these
values in the “Commissioning Report”.
3.1.7 Conservator & M.O.G.

Note details of M.O.G. in the “Commissioning Report”. If the M.O.G. is provided with a
locking lever, it should be removed. Mount the conservator. When there is as OLTC its
conservator is some times provided separately or by making a partitioned compartment in
the main conservator. OLTC conservator, if separate, should also be mounted.
3.1.8 Buchholz Relay

Note details of “Buchholz Relay” for the transformer and of “Oil Surge Relay” for the
OLTC in the “Commissioning Report.” Buchholz Relay floats are tied to prevent transit
damage. They should be released. Also if ‘ Test’ lever is provided, it should be in the
working position. Mount the “Buchholz Relay” and the shut off valves as described in
2.10 Similarly mount “Oil Surge Relay”.

Fig. 3.1 Buchholz Relay On Trasformer
3.1.9 Breathers
Note details of Breathers, in the “Commissioning Report.” If OLTC is provided, it may
have its own separate breather. Note details of these 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 OLTC
breather.
Fig. 3.2 Breathers

3.1.10 Radiators
Note the details of Radiators and Radiator Valves in the “Commissioning Report.” Mount
the radiators as outlined below:
(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.
(vi) Oil might seep through the tank side radiator valves and be retained by the
blanking plates. This oil should be collected in a clean container at the time of
removing top and bottom blanking plates.
(vii) Bring the radiator flanges close to the flanges on the tank. Ensure that tank gasket
is in position. Fit by means of bolts, nuts spring washers etc.
(viii) Open the bottom radiator valve using the operating handle. Gradually unscrew the
air release plug on the top of the radiator, until air starts escaping. Air release plug
should not be removed from the engaging threads as it would be difficult to
control oil coming out of it. Oil from main tank will now flow in the radiator,
driving out air form air release plug. When oil comes out steadily form the air
release plug and no more air comes through, close the air release plug. Open the
top radiator valve. Oil level in the conservator would now have fallen. Check that
there is no oil leakage from the radiator itself and the gasketted joints. Restore the
oil level and assemble the next radiator in the same manner.
Assembly of radiators should be preceded in only one direction-clockwise or

anticlockwise. After filling last radiator, oil level in conservator should be restored only
up to the filling mark.
When OLTC compartment is provided in the main conservator, this compartment is to be

separately filled up to its filling mark.
3.2 Commissioning
3.2.1 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.
3.2.2 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
3.2.3 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”.
3.2.4 Magnetising Current Test

Apply 415 volts, 2 phase, AC. to the H.V. terminals, keeping the L.V. terminals open and
tapping switch in the normal position. Measure the 3 line currents, if possible
simultaneously, otherwise one after the other. Because the 3 phases of the magnetic
circuit of the core are not similar, the 3 line currents will be approximately equal & v
phase current around 80% of either of them. If H.V. is delta connected, V & W phase
currents will be approximately equal and U phase current around 110 %
In case of Power Transformers, such a test is done, some times, along with routine tests at
the manufacturer works. When done at site and results compared with the factory test
confirms that there are no transit damages to the core and windings. Note the
observations in the “Commissioning Report”.

3.2.5 Magnetic Balance Test
This is a simple test to detect shorted turns is a winding. Its principle is that shorted turns
oppose establishment of flux in that limb because of the current that circulates through
the shorted turns.
As indicated in 3.3.2 apply single phase, 415 or 240 V. A .C. to such H.V. line terminals
which would energies U phase. (outer limb) Use an averaging instrument like a
Multimeter Measure the voltages induced in the V phase (Centre limb and W phase
(other outer lime). Measure also the current drawn by the energized phase. In case the
H.V. Voltage is 66 KV and above, the current drawn may be very small. In that case L.V.
would, generally, be 11 KV or more. This test can, then, be carried out on L.V. Side.
Centre limb being nearer to the energized limb, more flux passes through it and less flux
in the outer limb. The division is around 70-30 % & hence the measured voltages will be
having approx this proportion. Next, energies W phase and measure the other two
voltages as before. Results should be similar to previous ones. Then energies V phase
(Centre limb). As both the outer limbs are symmetrically located W.R.T. centre limb, flux
will divide equally between them. Hence the voltages measured on outer phases will be
approx. equal. Also, for reasons explained earlier, currents drawn when outer phases are
excited will be equal that for centre phase will be less (approx. 70 %). Thus these
observations will confirm the healthiness of the windings.
In case one of the phases has shorted turns, it will draw a comparatively large current
when it is energized. When other phases are energized, flux and hence voltage in the
shorted phase will be significantly reduced. Hence all three observations will indicate the
shorted phase. Note the observations in the “Commissioning Report”.
When the Magnetic Balance Test indicates a shorted phase, commissioning can not be
undertaken. Contact us immediately giving detailed test results.
3.2.6 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.

Fig. 3.3 Measurement of Insulation Resistance
3.2.7 Short-Circuit Test

For the H.V. side voltage and the % impedance, it would be possible to calculate the
current which would flow in the H.V. side, with 415V applied to it, while keeping L.V.
side shorted. If the 415 V source can feed that current, a short-circuit test can be carried
out.
This test would confirm proper contact engagement at all tap positions. Apply 3 ph. 415
V, 50 Hz to H.V. side, keeping L.V. side shorted. Measure the 3 line currents at all tap
positions. If the switch is an OFF-CIRCUIT switch, supply has to be disconnected before
changing tap. Note the observations in the “Commissioning Report”. Note also details of
OLTC, if any.
A Consistent trend indicates healthiness. If short-circuit test is not possible due to
limitation of source, carry out one tap changing operation over the entire range increasing
as well as decreasing. Check the other modes of OLTS operation and note in
“Commissioning Report”.

3.2.8 Parallel Operation
Sometimes the transformer to be commissioned is required to run in parallel with an
existing transformer. In is case, the following conditions must be fulfilled by the
incoming transformer.
(1) Its voltage ratio is same as the existing transformer on all tappings.
(2) Its % Impedance is within +1% of value of existing transformer.
NOTE: Due to difference in % impedances, when one transformer reaches its rated load,
the other would share less than its rated load. As a result, the combination can supply
load less than the sum of the two KVAs.
(3) Rated KVAs of the two transformers to be connected in parallel should not differ
by more than 1:3 as otherwise only marginal increase will be obtained in the
capacity of the combination.
(4) Vector group is compatible. If the vector groups of the two are such that terminals
to be paralleled have a phase different then they can not be connected in parallel.
Hence only certain Vector Groups are compatible with each other.
If possible, one should check zero voltage between the corresponding phases to be
paralleled.
3.3 Other Relevant Details
Other controlling and protecting equipments like C.T.s, Breakers, relays etc. from a part
of the transformer installation. Note their details in “Commissioning Report”
3.4 Check Points
After completing installation and pre-commissioning tests, check that the various points
mentioned in the “Commissioning Report” have been complied with. Compliance
nothings should be made in the “Commissioning Report”.
3.5 Energising
When all the pre-commissioning tests are found satisfactory and all the check points are
confirmed the transformer can be energized on No load. It is preferable to keep settings
of all protective relays to the minimum. The transformer should be allowed to run on No-
Load for about 3 hours. During this period, the transformer should be observed for any
abnormality in the hum and gas collection in the Buchholz Relay. Sometimes during this

period, trapped air is released and gets accumulated in Buchholz Relay.
At the end of this 3 hours period, transformer should be de-energised and air released
from Bushings, Bushing pockets, Buchholz Relay, Main tank cover, Radiators etc. The
transformer should, then, be energized again and then relays set at their desired setting.
Transformer should then be grandually loaded reaching full load in about 3 hours time.
During the period and for further 3 hours, (i.e. total of 6 hours) transformer should be
under observation. Check that all instruments, O.T.I & W.T.I, M.O.G. are reading
properly and that all radiators are uniformly hot. Check that there is no gas collection in
Buchholz Relay. If everything is found in order, the transformer can continue working.
The “Commissioning Report” should be duly signed by the Authorised representatives of
all the participating organizations.

CHAPTER-4
OPERATION & MAINTENANCE
4.1 OPERATION
I.S.2026-1977 states that a Power Transformers loaded at its rated KVA will fulfill its
normal life when its hottest spot temperature [ H.S.T.] is 98˙C for an air temperature of
32˙C As the ambient air temperature exceeds 32˙C the H.S.T. exceeds 98˙C The
insulation ageing { which decides the life of transformer}increased with increase of
H.S.T. increase of H.S.T. by 6˙C doubles the rate of ageing { i.e. reduces the life by
50%}. When the ambient air temperature is lower than 32˙C the H.S.T. is lower than
98˙C. The insulation ageing decreases thus increases the life of transformer.
It is considered {by the I.S. 6600-1973} that periods of accelerated ageing due to higher
ambient temperature are compested by the period of reduced ageing due to lower ambient
temperature.
Some times a transformer may be required to deliver load higher than its rating. Guidance
on overloading it provided by I.S. 6600 Basis for the recommendation is an follows.
In a 24 hours loading. If ambient temperature is low and loaded for a substantial time
duration is also low a short time over load may be permitted such that equivalent aging
due to this varying load will be the same as that of loading over a period of 24 hours.
4.2 Maintenance
4.2.1 General
Compared to most electrical equipments transformer requires relatively less maintenance.
However in order to obtain a long and trouble free service from the transformer. It must
be properly maintained. Maintenance consist of regular inspection testing and
reconditioning When necessary. Principal object of maintenance is to maintain the
insulation in good condition. Moisture dirt and high temperature causes insulation
deterioration i.e. ageing. Hence they must be prevented.
No work should be done on the transformer unless It is disconnected from all external
circuits and all windings have been solidly earthed.Naked lights and flames should be
kept well away from the transformer.
Precautions must be taken to secure tools with tapes to prevent them from falling inside
the tank.Maintenance hints on main constituents of the transformer are given in the
following paragraph.Recommended frequency of maintenance is given at the end of the
chapter. Detailed guidance on Maintenance is given in I. S. 10028 { part-II} – 1981.

4.2.2 OIL
In the transformer, oil is used as an insulating liquid as well as for cooling, It is necessary
to maintain required oil level and also to maintain this oil in good condition I.S. 1866.
gives recommendations in details for the maintenance of oil. A few guide lines are given
here.
i. Check if there is any leakage of oil. It noticed, corrective action must be
immediately taken
ii. The oil level should be checked at frequent intervals and if necessary,
topping up should be done with oil complying with I.S. 335.
iii. Samples of oil should be taken at regular intervals and tested.
iv. If the dielectric strength is below the value recommended in I.S. 1866, the
oil should be duly filtered. It may be noted that the products of
decompositions with, water acids etc. remain in the oil and accelerate the
rate of aging. Thus, timely treatment of oil is a must. The filteration will
remove moisture, dust sludge etc. Removal of sludge is important as
otherwise it can stick to coils and hamper the heat dissipation from coils.
However if the results indicate that acidity needs to be improved. Them a
simple filteration would not be sufficient and a Fullers Earth treatment
would be required.
4.2.3 Care & Winding

It id recommended that the core and windings are removed from the tank for visual
inspection as per the maintenance schedule given. Depending upon the arrangement
provided, tap switch handle, connections to bushings etc. may have to be disconnected
before lifting up core and wings assembly
The windings should be examined and if sludge has been deposited it should be washed
away with oil jet. Any loose nut and bolt should be tightened.
Adjust the rods/coil clamping screws provided to remove any slackness of windings. This
is important as slackness in winding will permit movement of coils under the action of
Short Circuits forces and repeated coil movement can wear out insulation and give rise to
a fault.
4.2.4 On Load Tap Changer

On load tap changer is, normally, mounted on the tank in the separate housing and
connected to winding leads through copper studs fixed on insulated terminal board.
Terminal board is oil-tight. Hence oil in the tank need not be lowered for attending O. I.
T. C.
In some other types O. I. T. C. is housed in the main tank by suitable mounting on the top
cover Here again O.L.T.C. oil in which arcing tanks place is not allowed to mix with the
man tank oil.
Please refer to O.L.T.C. menual for operation and maintenance instruction of O.L.T.C.

4.2.5 Conservator & Oil level Indicator
The Inside of conservator should be cleaned by flushing , clean Transformer oil to
remove sluge and other impurities. In bigger transformers, detachable end plate is
provided to facilitate cleaning of conservator.Oil gauge glass should be cleaned if then
glass is found broken, the same should be replaced.
Magnetic oil guage to be attended while cleaning the conservator. The mechanism should
be inspected and cleaned Float should be checked to see that there is no oil in the float.
This operation of alarm and trip contacts should to be checked.
4.2.6 Silica Gel Dehydrating Breather

Breather should be examined to ascertain if the silica gel requires changing. More
frequent inspection are needed when the climate is humid and when transformer is
subjected to fluctuating load. The colour of silica Gel crystals in the breather acts as an
indicator as an indicator as it changes from blue to pink when saturated with moisture.
When majority of crystal have turned pink. The silica gel should be reactivated by
beating in oven of a shallow pan at a temperature of 150’C to 200’C until the original
colour is gained. This usually takes 2 or 3 hours. Oil cup should be cleaned to remove
dust and dirty oil. Oil seal should be filled with fresh oil.

CONCLUSION
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.

REFERENCE
 Basic Electrical Engineering, by R.P. Ajwaliya
Chapter No. 14
Page No.367 to 415


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Chapter-1

1.1 Basics of Transformers

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

1.2 PRINCIPLE OF TRANSFORMER

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

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Figure 1.3: Transformer construction

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1.3 TYPES OF TRANSFORMER

A. Oil filled Transformers

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MANUFACTURING PROCESS OF TRANSFORMER

2.1 Winding Construction:-

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Helical Winding Layer Winding

Disc Winding Interleaved Winding

Fig. 2.1 Types of Winding

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Fig 2.2 Winding Construction

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Metalwork which becomes inadequately bonded, possibly due to shrinkage or vibration,

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Fig. 2.4 Core & Winding(Coil) Assembly

2.4 Tapping &Tap Changer:-

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

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Fig. 2.5 Tap Changer

2.5 Drying Process:-

2.5.1 Moisture removal

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Fig. 2.6 Theoretical drying curves with different drying periods.

2.5.1.1 Drying periods and implications optimal drying

I.Preheating period (drying rate is almost 0):

II.Constant-rate period (drying rate is constant in time):

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III.Falling-rate period (drying rate declines over time):

2.5.2 Drying rate and temperature

2.5.3 Uniform drying

During the drying process there is always variability in MC of individual grains.

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2.6 Tank Construction

2.7 Tanking & Final Fitting

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Fig. 2.7 Final Fitting

2.8 Fitting & Accessories:-

2.8.1 Rating & Terminal Marking Plate

Fig. 2.8 Rating & Terminal Marking Plate

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2.8.2.1 Off-circuit Switch

2.8.2.2 Off circuit ratio changing links

2.8.2.3 On load tap changer

Fig. 2.9 On-Load Tap Changer

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2.8.4 Lifting Lugs

Fig. 2.10 Valves

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2.8.6.1 Oil Communicating Type

2.8.6.2 Condenser Bushings

2.8.7 Cable Boxes