TESTING AND MAINTENANCE OF POWER

TRANSFORMERS

Submitted in partial fulfillment of the requirements for the award of

Bachelor of Engineering Degree in
Electrical and Electronics Engineering
By

SRIRAM R (43140031)

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

SCHOOL OF ELECTRICAL AND ELECTRONICS ENGINEERING

SATHYABAMA
INSTITUTE OF SCIENCE AND TECHNOLOGY
(DEEMED TO BE UNIVERSITY)
CATEGORY – 1 UNIVERSITY BY UGC
Accredited with Grade “A++” by NAAC | Approved by AICTE
JEPPIAAR NAGAR, RAJIV GANDHI SALAI, CHENNAI - 600 119.

OCTOBER - 2025
 DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that this Professional Training Report is the Bonafide work of
SRIRAM R (43140031) who carried out the Professional Training entitled on
“TESTING AND MAINTENANCE OF POWER TRANSFORMERS” at NLC
INDIA LIMITED, Neyveli from 26th MAY 2025 to 07th JUNE 2025.

Dr. V. SENTHIL NAYAGAM

Internal Guide

Head of the Department

Submitted for Viva voce Examination held on

Internal Examiner External Examiner

ii
iii
iv
 DECLARATION

I SRIRAM R (43140031) here by declare that the Professional Training Report

entitled done by me at NLC INDIA LIMITED, Neyveli and is submitted in partial
fulfillment of the requirements for the award of Bachelor of Engineering in
Electrical and Electronics Engineering.

DATE:

PLACE: SIGNATURE OF THE CANDIDATE

v
 ACKNOWLEDGEMENT

I am pleased to acknowledge my sincere thanks to Board of Management of

SATHYABAMA INSTITUTE OF SCIENCE AND TECHNOLOGY for their kind
encouragement in doing this Internship and for completing it successfully. I am
grateful to them.

I convey my thanks to Dr. N. M. Nandhitha, Dean, School of Electrical and

Electronics, and Head of the Department, Dept. of Electrical and Electronics
Engineering for providing me necessary support and details at the right time
during the progressive reviews.

I would like to express my sincere and deep sense of gratitude to Mr.

M.SIVARAMAKRISHNAN (Chief Manager / Electrical Mine II) from NLC INDIA
LIMITED, Neyveli for his valuable guidance, suggestions and constant
encouragement paved way for the successful completion of my Professional
Training.

I wish to express my thanks to all Teaching and Non-teaching staff members of

the Department of Electrical and Electronics Engineering, who were helpful in
many ways for the completion of the project.

vi
 ABSTRACT

This internship report outlines the technical knowledge and practical

experience gained during our internship at NLC India Limited, Mine-II, one of
the major lignite-based power-generating facilities in Tamil Nadu. The
internship was conducted in the Electrical Department, focusing specifically on
the operation, testing, and maintenance of power transformers in a
230 kV/11 kV substation environment.
During the internship, we explored various key components of power
transformers such as conservator tanks, silica gel breathers, On Load Tap
Changers (OLTC), bushings, radiators, explosion vents, and protective devices
like Buchholz relays and differential relays. We were introduced to the working
principles, configuration, and protective mechanisms essential to ensure the
reliable and safe operation of power transformers used in high-voltage
applications.
A significant part of the internship involved learning and observing transformer
testing procedures that are regularly performed to assess the operational
health of transformers. These procedures helped us understand how early fault
detection and preventive maintenance ensure prolonged transformer life and
avoid major breakdowns.
This internship served as a valuable bridge between theoretical concepts
taught in the classroom and the actual working conditions of a high-voltage
substation. It provided us with a strong foundation in the technical aspects of
transformer diagnostics, protection, and preventive maintenance, which are
essential for any aspiring electrical engineer entering the power or utility
sector.

vii
TABLE OF CONTENTS

viii
CHAPTER TITLE Page
NO No.

ABSTRACT vii

LIST OF FIGURES xiii

LIST OF TABLES xv

1 INTRODUCTION 1

1.1 BACKGROUND 1

1.2 PURPOSE OF THE INTERNSHIP 1

1.3 LEARNING EXPECTATIONS 2

2 ORGANIZATION PROFILE 3

2.1 INTRODUCTION TO NLC INDIA LIMITED 3

2.1.1 INTRODUCTION 3

2.1.2 MINE – I, IA & II INCLUDING EXPANSION 3

2.2 MISSION, VISION & CORE VALUES 4

2.2.1 MISSION 4

2.2.2 VISION 5

2.2.3 CORE VALUES 5

2.3 POWER GENERATION 5

CHAPTER TITLE Page

NO No.

2.3.1 THERMAL POWER STATION-I EXPANSION 5

ix
 2.3.2 THERMAL POWER STATION-II 5

2.3.3 TPS-II EXPANSION 6

2.4 SUB STATION DETAIL & TOWER 6

2.4.1 MINE-II-230KV SUBSTATION, NLC INDIA 6

LTD, NEYVELI

2.4.2 SALIENT FEATURES OF 230KV 6

SUBSTATION

2.4.3 CHRONOLOGICAL ORDER OF 6

COMMISSIONING OF SUBSTATION

2.4.4 230KV Substation Components & their 9

Workings

3 INTERNSHIP OBJECTIVES 10

3.1 PRACTICAL EXPOSURE 10

3.2 CONSTRUCTION OF TRANSFORMERS 11

3.2.1 CORE 11

3.2.2 STEEL LAMINATED CORE 12

3.2.3 DISC AND CONTINUOUS WINDING 12

3.2.4 TRANSFORMER OIL 13

3.2.5 MINERAL OIL 14

3.2.6 SYNTHETIC OIL 14

CHAPTER TITLE PAGE

NO NO.

3.3 TRANSFORMERS PARTS 14

x
 3.3.1 CONSERVATOR 15

3.3.1.1 WORKING 15

3.3.1.2 OIL LEVEL 15

3.3.2 BREATHER 16

3.3.3 TAP CHANGER 17

3.3.4 DE-ENERGIZED NO LOAD TAP 17

CHANGERS

3.3.5 COOLING TUBES 17

3.3.5.1 COOLING METHODS FOR OIT 18

3.3.5.2 ONAN 18

3.3.6 BUCHHOLZ RELAY 19

3.3.6.1 WORKING 19

3.3.6.2 OPERATION 19

3.3.7 EXPLOTION VENT 20

3.3.8 GASKETS 21

3.3.9 BUSHING 22

4 TECHNICAL LEARNINGS 23

CHAPTER TITLE PAGE

NO NO.

4.1 SUBSTATION TRANSFORMER: TESTING & 23

MAINTENANCE EXPERIENCE

xi
 4.2 THE IMPORTANT TRANSFORMERS 24
PROTECTIONS

4.2.1 OVER CURRENT/ EARTH FAULT 24

PROTECTION

4.2.2 DIFFERENTIAL PROTECTION 24

4.2.3 OVER – FLUXING PROTECTION 25

4.2.4 RESTRICTED EARTH FAULT PROTECTION 25

AND NCT OPERATED EARTH FAULT
PROTECTION

4.3 TRANSFORMER MAINTENANCE TESTINGS 26

4.3.1 INSULATION RESISTANCE TEST 26

4.3.2 DIRECT CURRENT RESISTANCE TEST 27

4.3.3 RATIO TEST 27

4.3.4 MAGNETIC BALANCE TEST 28

4.3.5 VECTOR GROUP TEST 29

4.3.6 DIELECTRIC STRENGTH TEST 30

4.4 MAINTENANCE OF LARGE TRANSFORMER 31

4.5 DETAILS OF ROUTINE CHECKS 31

4.5.1 DAILY CHECKS 31

CHAPTER TITLE PAGE

NO NO.

4.5.2 FORTNIGHTLY CHECKS 31

4.5.3 MONTHLY CHECKS 32

xii
 4.6 PERIODICAL TESTS AND MAINTENANACE 32

4.6.1 HALF YEARLY TEST AND MAINTENANCE 32

4.6.2 ANNUAL TESTS AND MAINTENACE 32

4.7 PRE-STARTING TESTS AND CHECKS AFTR AN 33

IDLE PERIOD OF ONE MONTH OR MORE

4.8 MAJOR OVERHAUL 33

5 CONCLUSIONS 34

5.1 SKILLS GAINED 34

5.2 CAREER ALIGNMENT 34

5.3 RECOMMENDATIONS 35

REFERENCES 36

xiii
 LIST OF FIGURE

FIGURE TITLE PAGE

NO. NO.

1.1 On-site visit to NLCIL 230/11 kV Substation (Mine-II), 2

Neyveli

2.1 Power Transformer – Step-down voltage conversion 7

2.2 3.230KV Isolator, Circuit Breaker and CT 8

2.3 4.11 kV Yard – Distribution and control 8

2.4 Conservator Tank – Oil level regulation 9

3.1 Steel Laminated Core – Provides low reluctance path 12

3.2 Disc & Continuous Winding – Ensures strength and 13

insulation
3.3 Transformer Oil – Provides cooling and electrical 13
insulation
3.4 Oil Level – Indicates transformer oil quantity accurately 16

3.5 Breather – Removes moisture from incoming air 16

3.6 Tap Changer – Regulates output voltage under load 17

3.7 Cooling Tubes – Dissipates heat through oil circulation 18

3.8 Buchholz Relay – Detects internal transformer faults early 20

3.9 Buchholz Relay – Activates alarm during internal faults 20

xiv
FIGURE TITLE PAGE
NO. NO.
3.10 Explosion Vent – Releases excess pressure during faults 21

3.11 Gaskets – Prevents oil leakage and moisture entry 21

3.12 Bushing – Provides insulated high-voltage connection 22

4.1 IR Test Kit – Measures insulation resistance of windings 26

4.2 DCR Test Kit – Checks winding resistance for faults 27

4.3 Ratio Test Kit – Verifies transformer voltage 28

transformation ratio

4.4 Magnetic Balance Test – Checks core symmetry and 29

winding faults

4.5 Vector Group Test – Confirms winding configuration and 30

phase displacement

4.6 Dielectric Strength Test – Measures insulating strength of 30

transformer oil

xv
 LIST OF TABLE

TABLE TITLE PAGE

NO. NO.

2.1 Substation Electrical Equipments (230 kV / 11 kV Sides) 9

xvi
 CHAPTER 1

INTRODUCTION
1.1 BACKGROUND

The modern electrical power system requires the use of high-voltage

transformers for the safe and efficient transfer of electricity across generation,
transmission, and distribution networks. Power transformers play a key role in
stepping up and stepping down voltage levels to match system requirements and
minimize losses. In industrial environments such as mining and power generation
units, transformer reliability is critical to prevent equipment failure and power
outages.
NLC India Limited is a Navratna Government of India enterprise engaged in
lignite mining and power generation. The Mine-II division of NLC operates a
230 kV/11 kV substation to supply power to mining equipment such as conveyors,
pumps, and draglines.
The substation houses 25 MVA and 30 MVA power transformers that are
maintained through strict testing and protection schedules. As electrical
engineering students, gaining practical exposure to such transformer systems
helps bridge the gap between classroom learning and real-world applications.

1.2 PURPOSE OF THE INTERNSHIP

The purpose of this internship was to acquire hands-on knowledge of the

working, testing, and maintenance procedures of high-voltage power transformers
in a substation environment. Through this internship, we were able to observe the
actual equipment used in large-scale transformers such as On Load Tap
Changers (OLTC), radiators, breather systems, bushings, and various protection
devices like Buchholz relays and differential relays.
We also learned how standard testing procedures are performed to ensure
transformer safety and reliability. These included insulation resistance testing, ratio
testing, winding resistance measurement, magnetic balance, vector group
identification, breakdown voltage testing of transformer oil, tan delta testing, and
earth resistance measurement.

1
 Observing these tests allowed us to understand how predictive
maintenance plays a vital role in transformer health.
1.3 LEARNING EXPECTATIONS

Before beginning the internship, our primary learning expectations were to:
 Understand the real-time functioning and structure of a 230 kV/11 kV power
transformer.
 Learn about the protection schemes and safety measures applied in a
substation.
 Gain exposure to industrial transformer testing techniques and the instruments
used..
 Learn the schedule and procedures followed during daily, monthly, and annual
transformer maintenance.
By the end of the internship, we expected to develop both technical knowledge
and practical confidence in dealing with transformer-related operations, as
illustrated in Fig. 1.1, which are essential skills for any future electrical engineer
entering the power or utility industry.

Fig 1.1 : On-site visit to NLCIL 230/11 kV Substation (Mine-II), Neyveli

2
 CHAPTER – 2

ORGANIZATION PROFILE

2.1 INTRODUCTION TO NLC INDIA LIMITED

2.1.1 INTRODUCTION

NLC India Limited, a "NAVRATNA" Government of India enterprise,

under the administrative control of MOC has a checkered history of
achievements since 1956. Demand for electrical power is increasing at a
rapid pace in our country. To meet the rapid increase, installation of more
thermal power station is the only choice. Neyveli has exclusively proven
reserves of Lignite having low calorific value and is located near to the load
canter thus minimizing the capital cost of transportation lines and reduction
in transportation losses.
There are three open cast lignite mines of total capacity of 28.5 million
tons per annum at Neyveli and one open cast lignite mine of capacity 2.1
million tons per annum at Barsingsar, Rajasthan. They meet nearly 30-40
percent of Tamil Nadu power requirement, Thermal power station - 1 power
generation started from August - 1962, Thermal power station - II generation
started from March 1986, Thermal power station - I Expansion generation
started from June 2003.
The first mine produces about 8.5 million tons of lignite per annum and
the second produces about 10.7 million tons of lignite per annum, the mine-
IA produces about 3 million tons of lignite per annum. The electrical mines
base consists of service yard of LT and HT motors and cables and protection
switchgears, substation for the mining of the lignite the raw material used for
heating of water through boilers.

2.1.2 MINE – I, IA & II INCLUDING EXPANSION

The lignite seam was first exposed in August 1961 and regular mining
of lignite commenced in May 1962. German excavation technology in open
cast mining, using Bucket Wheel Excavators, Conveyors and Spreaders
were used for the first time in the country in Neyveli Mine-I. The capacity of
this mine was 6.5 MT which met the fuel requirement of TS-I. The capacity
3
was increased to 10.5MT of lignite per annum from March 2003 under Mine-I
expansion scheme and at present meets the fuel requirement for generating
power from TPS-I and TPS-I Expansion.
Government of India sanctioned the project Mine-I A of 3 million
tonnes of lignite per annum at a sanctioned cost of Rs. 1032.81 crores in
February'98.

This project is mainly to meet the lignite requirement of M/s ST-CMS

for their power plant and also to utilize the balance lignite to the best
commercial advantage of NLC. The project was completed on 30th March
2003 within time and cost schedule.
In February, 1978 Government of India sanctioned the Second Lignite
Mine of capacity 4.7 MT of lignite per annum and in February `83,
Government of India sanctioned the expansion of Second Mine capacity
from 4.7 to 10.5 Million Tonnes. Unlike Mine-I, Mine-II had to face problems
in the excavation of sticky clayey soil during initial stage.
The method of mining and equipment used are similar to that of Mine-
I. The seam is the same as of Mine-I and is contiguous to it. The lignite
seam in Mine-II was first exposed in September 1984 and the excavation of
lignite commenced in March, 1985.
GOI sanctioned the expansion of Mine-II from 10.5 MTPA to 15.0
MTPA of lignite in October 2004 with a cost of Rs. 2295.93 crore. Mine-II
Expansion project was completed on 12th March 2010. The lignite excavated
from Mine-II meets the fuel requirements of Thermal Power Station-II and
Thermal Power Station–II Expansion under implementation.

2.2 MISSION, VISION & CORE VALUES

2.2.1 MISSION
To generate reliable, affordable, and environmentally responsible power by
utilizing India’s vast lignite reserves through cutting-edge thermal and renewable
technologies. We aim to meet the growing energy needs of southern India while
maintaining sustainability and operational excellence.

4
2.2.2 VISION

To be a world-class energy enterprise recognized for innovation, clean

energy leadership, and high-efficiency thermal power generation using indigenous
fuel resources like lignite. We strive to support India's power infrastructure through
responsible mining and continuous capacity expansion.

2.2.3 CORE VALUES

 Technological Advancement
 Sustainability
 Reliability and Grid Support
 Growth through Capacity Expansion

2.3 POWER GENERATION

2.3.1 THERMAL POWER STATION-I EXPANSION

Thermal Power Station-I has been expanded (2 x 210 MW) using the
lignite available from Mine-I Expansion. The scheme, TPS I Expansion, was
sanctioned by Government of India in February 1996. Unit-I was
synchronized in October 2002 and Unit-II in July 2003. The power generated
from this Thermal Power Station, after meeting the internal requirements, is
shared by the Southern States viz., Tamil Nadu, Kerala, Karnataka, and
Union Territory of Pondicherry.

2.3.2 THERMAL POWER STATION-II

The 1470 MW Second Thermal Power Station consists of 7 units of

210 MW each. In February 1978, Government of India sanctioned the
Second Thermal Power Station of 630 MW capacity (3 X 210 MW) and in
Feb.'83, Government of India sanctioned the Second Thermal Power Station
Expansion from 630 MW to 1470 MW with addition of 4 units of 210 MW
each. The first 210 MW unit was synchronized in March 1986 and the last
unit (Unit-VII) was synchronized in June'93.
The power generated from Second Thermal Power Station after

5
meeting the needs of Second Mine is shared by the Southern States viz.,
Tamil Nadu, Kerala, Karnataka, Andhra Pradesh and Union Territory of
Pondicherry.

2.3.3 TPS-II EXPANSION

This Project is consisting of two units of 250 MW capacity each. Unit-II

attained commercial operation in April 2015 and Unit-I in July 2015. The
lignite requirement is met through expansion of Mine-II. The steam
generators of this project employ eco friendly Circulating Fluidized Bed
Combustion (CFBC) technology. This technology has been adopted for 250
MW Capacity units for the first time in India.

2.4 SUB STATION DETAIL & TOWER

2.4.1 MINE-II-230KV SUBSTATION, NLC INDIA LTD, NEYVELI

230/11KV SUB STATION is the power supply distribution center for

MINE- II of N.L.C India Ltd. The substation receives supply from Thermal
Power Station-II through 230KV feeders namely MF-3 and MF-4.

2.4.2 SALIENT FEATURES OF 230KV SUBSTATION

Installed Capacity : 340 MVA

Number of 230KV Feeders : Two (namely MF-3 and MF-4 from
TS-II)
Number of Power Transformers : 12
Area of the substation : 52000 sq. m
Insulation Level : 245/ 460/ 1050KV
Fault Level : 40KA

2.4.3 CHRONOLOGICAL ORDER OF COMMISSIONING OF SUBSTATION

Stage I :-
During the year 1984-85, Transformers 3,4,5,6 were installed in the main
Substation.
Transformer Capacity : 25 MVA, 230/11KV

6
No. of Transformers : 4 x 25 MVA
Stage II :-
During the year1989-90, Transformers1,2,7,8 were installed in the main
substation.
Transformer Capacity : 30 MVA, 230/11KV
No. of Transformers : 1 No.25 MVA & 3 Nos. 30 MVA
Stage III :-
During the year 2007-08, Transformers 11,12,13,14 were installed in the
expansion. substation.
Transformer Capacity : 30 MVA, 230/11KV
No. of Transformers : 4 x 30 MVA
The 230KV substation yard is shown in the figures.

Fig. 2.1 : Power Transformer – Step-down voltage conversion

Fig. 2.1 shows a 230/11 kV power transformer used in the substation
to step down high voltage for industrial use. It plays a vital role in enabling
safe power transmission to mining operations. The transformer is built with
cooling, protection, and tap-changing mechanisms to ensure reliable
performance under heavy load.

7
 Fig. 2.2 : 3.230KV Isolator, Circuit Breaker and CT
Fig. 2.2 shows the 230 kV isolator, circuit breaker, and current
transformer (CT) used in the high-voltage side of the substation. The isolator
disconnects equipment for maintenance, while the SF₆ circuit breaker
interrupts fault currents. The CT measures line current for protection and
monitoring purposes.

Fig. 2.3 : 4.11 kV Yard – Distribution and control

Fig. 2.3 shows the 11 kV yard of the substation, which includes busbars,
breakers, isolators, and outgoing feeders. This section distributes the stepped-
down voltage to various mining equipment. It also includes protective relays and
control panels to ensure safe operation and load management.

8
 Fig. 2.4 : Conservator Tank – Oil level regulation
Fig. 2.4 shows the conservator tank mounted above the transformer
main tank. It accommodates the expansion and contraction of transformer oil
due to temperature changes. The conservator helps maintain proper oil
levels and reduces oxidation by limiting oil exposure to air.

2.4.4 230KV Substation Components & their Workings

230KV Substation is a network of electrical equipments which are

connected in a structured way to supply electric power to Mine-II.The
following are major components installed in substation switch yard and the
details &working principle of each component is explained in detail as a List.

Table:2.1: Substation Electrical Equipments (230 kV / 11 kV Sides)

230 kV Side Components 230 kV Side Components

Incomer Lines Bus Conductors
Lightning Arresters Group Control Breakers
Capacitor Voltage Transformers AB Switch / Isolators
Bus Conductors Multiunit Feeder Panels
Isolators Lightning Arresters
SF6 Circuit Breakers Control and Relay Panel
Power Transformers
Control and Relay Panel

9
 CHAPTER -3

INTERNSHIP OBJECTIVES

3.1 PRACTICAL EXPOSURE

During our internship at the 230 kV/11 kV substation at NLC Mine-II, we had
the opportunity to observe and understand the core principles and working
mechanisms of power transformers installed in an industrial setting.
We observed that a transformer is a passive electrical device used to transfer
electrical energy from one circuit to another through electromagnetic induction. In
the substation, step-down transformers are used to reduce the high transmission
voltage (230 kV) to a medium voltage level (11 kV) suitable for operating mining
equipment.
Our mentors explained that the working principle is based on Faraday’s
Law of Electromagnetic Induction, where an electromotive force (EMF) is induced
in the secondary coil when the magnetic flux linking the coil changes. This
magnetic flux is created by alternating current flowing through the primary winding.
The mutual inductance between the primary and secondary coils allows the
energy to be transferred efficiently.
We also understood how the number of turns in the windings determines
whether a transformer is step-up or step-down:
 If the primary winding has more turns than the secondary, the voltage
decreases (step-down).
 If the secondary winding has more turns, the voltage increases (step-up).
In real-world conditions, almost all the magnetic flux generated in the
primary winding links with the secondary winding by using a laminated magnetic
core. This helps minimize core losses and ensures efficient energy transfer. We
were also informed about transformer inrush current—an initial high current drawn
by the transformer when energized, due to flux imbalance.

Additionally, we carefully studied the transformer nameplate, which contains

critical technical data. For transformers rated above 500 kVA, the following
information was listed:

10
  Name of manufacturer
 Serial number and year of manufacture
 Number of phases
 Power rating (kVA or MVA)
 Frequency and voltage ratings (HV/LV)
 Tap voltages and vector group
 Cooling class (e.g., ONAN)
 Rated temperature rise (°C)
 Polarity and phasor diagram
 Percentage impedance
 Weight of transformer
 Type of winding conductor
 Oil volume
 Installation and operating instructions
Reading and interpreting the nameplate helped us understand how a
transformer is specified, rated, and identified for its intended operation. This
hands-on exposure made the theoretical concepts more tangible and relevant to
industrial applications.

3.2 CONSTRUCTION OF TRANSFORMERS

3.2.1 CORE

The transformer core is a closed magnetic circuit through the mural flux
ie., the flux which links with both the winding passes. The core material and
construction should be such that both the magnetizing current and the core losses
are mini. This implies, that the thickness of the lamination should be extremely
small to reduce the eddy current losses to a minimum. This practical limit of
thickness is 0.3 mm.
The thickness of the laminations are from 0.33-0.5 mm. The thickness
should not be reduced below 0.3 mm because in that case, the lamination become
mechanically weak and tend to buckle. These lamination are made of the so-called
transformer grade steel containing 3-5% silicon. The higher content of silicon
increases the resistivity of the core, thereby reducing the eddy current core loss.

11
3.2.2 STEEL LAMINATED CORE

These types of transformer cores are known for their permeability, which
reduces the magnetizing current and makes them a suitable option to use in
transmitting voltage at the audio frequency level.

Fig. 3.1 : Steel Laminated Core – Provides low reluctance path

Fig. 3.1 shows the steel laminated core of a transformer, which forms the
magnetic path for flux linkage between windings. Laminations are used to
minimize eddy current losses and improve efficiency. The core plays a key role in
electromagnetic induction and transformer performance.

3.2.3 DISC AND CONTINUOUS WINDING

The Disc and Continuous Disc Winding is used for high-capacity
transformers. These windings consist of numerous flat coils/ discs in a series or
parallel formation. The coils of these windings are formed with the help of
rectangular strips that are wound spirally from the center outwards in a radial
direction. The conductors of these windings can be a single strip or multiple strips
in a parallel formation that is wound on the flat side.
This formation of the conductors makes the construction for this type of
windings extremely strong. The discs are separated from each other with the help
of press-board sectors that are attached to vertical stripes.
The area of the conductor ranges from 4 to 50 mm square and limits for
current are 12 to 600 A. The minimum oil duct width is 6 mm for 35 kV. The
advantage of these windings is that they provide greater mechanical axial strength
and cheapness.

12
 Fig. 3.2 : Disc & Continuous Winding – Ensures strength and
insulation
Fig. 3.2 shows disc and continuous windings used in transformers. Disc
winding is typically used for high-voltage windings to provide better mechanical
strength and cooling. Continuous winding is common in low-voltage sides and
ensures uniform insulation and electrical stability.

3.2.4 TRANSFORMER OIL

The transformer oil insulates as well as cools the core and coil assembly.
The core and windings of the transformer must be completely immersed in the oil
that normally contains hydrocarbon mineral oils. In our transformer repair bay, we
use naphthalene oil.

Fig. 3.3 : Transformer Oil – Provides cooling and electrical insulation

Fig. 3.3 shows transformer oil, which serves as both an insulating and
cooling medium inside the transformer. It helps prevent electrical breakdown
between internal components and dissipates heat generated during operation.
Regular testing of oil quality is essential for safe and efficient transformer

13
performance.

3.2.5 MINERAL OIL

These are petroleum products, like Naphthenic-based transformer oil
and Paraffinic-based transformer oil. Naphthenic-based transformer oils are
known for their heat distribution, which is one of the main problems with
transformers. This also has a good flowing feature under low temperature and
it is wax-free. These types of oils are better for low-temperature. Even though
it oxidizes easier, the product formed by this process (i.e sludge) is soluble.
Hence, it won’t obstruct the cooling system of the transformer.
Paraffinic-based transformer oil is obtained from paraffinic crude oil
using solvent separation methods. This is known for its good thermal and
oxidation durability and good high-temperature viscosity feature. Because of
its high viscosity index due to the presence of wax, though the oxidation rate is
lower than the naphthenic oils, the precipitant or the sludge is formed due to
the oxidation. This might become an obstruction for heat dissipation. Since the
rate of oxidation is low, cost-effective, and available, this oil is widely used in
India.

3.2.6 SYNTHETIC OIL

Synthetic oils which are generally silicone-based were popular in the
middle of the 70s. This is generally used in the fire-prone area because of its
fire-retardant properties. It also has a few problems of low heat dissipation and
high moisture absorbing capacity. It is also costlier than mineral oil.

3.3 TRANSFORMERS PARTS

o Conservator
o Breather
o Tap changer
o Cooling tubes
o Buchholz relay
o Explosion vent

14
o Gaskets
o Bushes

3.3.1 CONSERVATOR

A conservator tank can be defined as, a tank that is placed on the

transformer’s roof to provide sufficient space for oil expansion in the
transformer. The main function of the conservator tank of a transformer is,
once the transformer is loaded and the ambient temperature rises, then the
volume of the transformer oil will increase.
So it works like a reservoir for insulating the transformer oil. The shape
of the conservator tank in the transformer is cylindrical where both the ends of
the oil container are closed. The pipe of the conservator comes from the main
tank of the transformer. It is placed in the conservator tank at the bottom part.
Generally, the fixing pipe of the silica gel breather goes into the conservator
tank from the top. When this pipe goes from the base, then it should be
projected well on top of the oil level in the tank. This the arrangement ensures
that transformer oil does not flow into a silica gel breather even at the
maximum operating level.

3.3.1.1 WORKING

The working of the conservator tank is, once the transformer insulating
oil increases because of the ambient temperature and load, then the vacant
space on top of the oil level in the conservator is incompletely occupied
through the extended oil. Once the transformer load reduces, then the
transformer is turned off similarly, once the ambient temperature reduces, the
transformer oil contracts.

3.3.1.2 OIL LEVEL

Maintaining the transformer oil level within the conservator tank is not
important but there must be some amount of oil for proper operation..

15
Here, the level of transformer oil mainly depends on the temperature of oil,
solar radiation, transformer loading, ambient temperature, etcThe design of
this tank mainly depends on the change in the transformer oil level. According
to the International Electro technical Commission (IEC), conservator tank
design must use the temperature which ranges from -25°C to +110°C.

Fig. 3.4 : Oil Level – Indicates transformer oil quantity accurately

Fig. 3.4 The oil level indicator shows the quantity of insulating oil
present inside the transformer conservator tank. Maintaining the correct oil
level is essential for effective cooling and insulation. A low oil level may
indicate leakage or high internal temperature, which requires immediate
attention.

3.3.2 BREATHER

Under normal transformer operating conditions, insulating oil

temperature regularly changes with fluctuations in load and ambient
conditions. During heavy loading conditions, the oil temperature rises, which
causes an increase in oil volume inside the transformer.
During the breathing cycle of a transformer, it is crucial to prevent
atmospheric moisture from entering the transformer, which can contaminate
the oil and cause damage over time to internal parts. The transformer windings
are insulated with cellulose paper and fully submerged in insulating oil, both of
which have very high dielectric strengths. The easiest way for atmospheric
moisture to enter the transformer is through a fully saturated traditional
breather that is past its maintenance requirement. When the silica gel inside a
traditional breather is fully saturated, it will no longer absorb atmospheric
moisture as it enters the transformer and must be replaced. Depending on the
breather, color-changing silica can sometimes be fully saturated internally and
show no color change externally.

16
 Fig. 3.5 : Breather – Removes moisture from incoming air
Fig. 3.5 The oil level indicator shows the quantity of insulating oil
present inside the transformer conservator tank. Maintaining the correct oil
level is essential for effective cooling and insulation. A low oil level may
indicate leakage or high internal temperature, which requires immediate
attention.
3.3.3 TAP CHANGER

The purpose of a tap changer is to regulate the output voltage of a

transformer by altering the number of turns in one winding and thereby
changing the turns ratio of the transformer. There are two types of tap
changers: a de-energized tap changer (DETC) and an on-load tap changer
(OLTC).

3.3.4 DE-ENERGIZED NO LOAD TAP CHANGERS

Transformer Solutions’ de-energized tap changers are designed to last

with no maintenance under normal operating conditions. The tap changer, a
manually operated device, includes an external operating handle with a
marked position-indicating dial.

Fig. 3.6 : Tap Changer – Regulates output voltage under load

Fig. 3.6 shows the tap changer of a transformer, which is used to
regulate the output voltage by changing the turn ratio between the windings. It
ensures voltage stability under varying load conditions. On-load tap changers
allow adjustment without interrupting the transformer’s operation.

17
3.3.5 COOLING TUBES

No transformer is truly an ideal transformer and hence each will incur

some losses, most of which gets converted into heat. If this heat is not
dissipated properly, the excess temperature in the transformer may cause
serious problems like insulation failure. The transformer needs a cooling
system. Transformers can be divided into two types as (i) dry-type
transformers and (ii) oil-immersed transformers. Different cooling methods of
transformers are –
For dry type transformers
 Air Natural (AN)
 Air Blast
For oil immersed transformers
 Oil Natural Air Natural (ONAN)
 Oil Natural Air Forced (ONAF)
 Oil Forced Air Forced (OFAF)
 Oil Forced Water Forced (OFWF)

3.3.5.1 COOLING METHODS FOR OIL IMMERSED TRANSFORMERS

In our transformer repair bay, we mostly use Oil Natural Air Natural
(ONAN) method only.

3.3.5.2 OIL NATURAL AIR NATURAL (ONAN)

This method is used for oil-immersed transformers. In this method, the

heat generated in the core and winding is transferred to the oil. According to
the principle of convection, the heated oil flows in the upward direction and
then in the radiator.
The vacant place is filled up with cooled oil from the radiator. The heat from
the oil will dissipate in the atmosphere due to the natural airflow around the
transformer.

18
 Fig. 3.7 : Cooling Tubes – Dissipates heat through oil circulation
Fig. 3.7 shows the cooling tubes (radiators) attached to the transformer
tank. These tubes help dissipate the heat generated during operation by
allowing transformer oil to circulate and release heat to the surrounding air.
Efficient cooling maintains insulation strength and prevents overheating.
3.3.6 BUCHHOLZ RELAY

Buchholz relay is a type of oil and gas actuated protection relay

universally used on all oil-immersed transformers having a rating of more than
500 KVA. Buchholz relay is not provided in relays having a rating below 500
KVA from the point of view of economic considerations.

3.3.6.1 WORKING

Buchholz relay is used for the protection of transformers from the faults
occurring inside the transformer. Short circuit faults such as inter-turn faults,
incipient winding faults, and core faults may occur due to the impulse
breakdown of the insulating oil or simply the transformer oil. Buchholz relay will
sense such faults and close the alarm circuit.

3.3.6.2 OPERATION

The operation of the Buchholz relay is very simple. Whenever any minor
fault occurs inside the transformer heat is produced by the fault currents. The
transformer oil gets decomposed and gas bubbles are produced.
These gas bubbles move towards the conservator through the pipeline.
These gas bubbles get collected in the relay chamber and displace oil
equivalent to the volume of gas collected.

19
 The displacements of oil tilt the hinged float at the top of the chamber
thereby the mercury switch closes the contacts of the alarm circuit. In case of
minor faults, the float at the bottom of the chamber remains unaffected
because the gases produced will not be sufficient to operate it. This trip circuit
will operate the circuit breaker and isolate the transformer.

Fig. 3.8 : Buchholz Relay – Detects internal transformer faults early

Fig. 3.8 shows the Buchholz relay, a gas-actuated protection device
installed between the main tank and the conservator of the transformer. It detects
internal faults such as insulation failure or short circuits by sensing gas
accumulation or oil flow. The relay triggers alarms or trips the transformer to
prevent damage.

Fig. 3.9 : Buchholz Relay – Activates alarm during internal faults

Fig. 3.9 shows another view of the Buchholz relay, highlighting its
position and connection within the transformer oil circuit.

3.3.7 EXPLOTION VENT

20
 An explosion vent is a non-reusable safety device designed to burst at a
set pressure along a specific rupture line, relieving pressure and providing a
pathway for deflagration hazards to safely escape.
Advantages - Vents can open with almost no inertia, so they are suitable for all
sizes of vessel and for all positions on that vessel. They also are free of
moving parts. They are far less affected by the weather or other wear and tear
found in explosion doors, and they require minimal maintenance.

Fig. 3.10 : Explosion Vent – Releases excess pressure during

faults
Fig. 3.10 shows the explosion vent, a protective device designed to
relieve internal pressure buildup in the transformer during severe faults. It
prevents catastrophic failure by safely releasing gases and oil in case of an
internal explosion. This enhances the overall safety of the transformer and
nearby equipment.

3.3.8 GASKETS

A secondary function of a transformer gasket is to prevent the entry of

moisture into the transformer housing. The entry of moisture and humidity into
a transformer accelerates the aging and breakdown of the insulating materials
used within the transformer, leading to outright failure. In transformer repair
bay 3mm or 5mm gasket used for connecting points of Bushing , Buchholz
relay, cooling fins etc. The 10mm or 8mm gaskets are being used for top cover
of the transformer.

21
 Fig. 3.11 : Gaskets – Prevents oil leakage and moisture entry
Fig. 3.11 shows the gaskets used in a transformer to provide airtight
and oil-tight seals between joints and components. These gaskets prevent oil
leakage and moisture ingress, which are critical for maintaining insulation
quality and reliable operation. Proper gasket condition is essential for
transformer longevity.
3.3.9 BUSHING

Bushings Transformers are connected to high voltage lines, and,

therefore, care must be taken to prevent flashover from the high voltage
connection to the earthed bank Connections for cables are made in cable
boxes, but overhead connections must be brought through bushings
specifically designed for various voltage classes. The bushing consists of a
current-carrying part in the form of a conducting rod, bus, or cable, a porcelain
cylinder installed in a hole in the transformer cover, and used for isolating the
current-carrying part. The simplest bushing is a moulded, high-quality glazed
porcelain insulator with a through its centre. This bushing is used for voltages
up to 33 kV.

Fig. 3.12 : Bushing – Provides insulated high-voltage connection

Fig. 3.12 shows the bushing, an insulating device that allows high-
voltage conductors to pass through the transformer tank without electrical
contact. It provides both electrical insulation and mechanical support.
Bushings are critical for safely connecting internal windings to external circuits.

22
23
 CHAPTER – 4

TECHNICAL LEARNINGS

4.1 SUBSTATION TRANSFORMER: TESTING & MAINTENANCE EXPERIENCE

During our internship at NLC India Limited – Mine II, we gained valuable
hands-on insights into the working, construction, testing, and maintenance of
power transformers in a real-time 230 kV/11 kV substation environment. The
technical learning experience bridged the gap between academic knowledge and
field-level engineering practices.

We began by understanding the basic working principle of transformers

based on Faraday’s Law of Electromagnetic Induction. We learned how mutual
induction between primary and secondary windings enables voltage
transformation. In the substation, step-down transformers were used to reduce the
230 kV transmission voltage to 11 kV for mining operations.

We studied in detail the physical components of a power transformer,

including the core, windings, conservator tank, silica gel breather, Buchholz relay,
On Load Tap Changer (OLTC), radiators, cooling fans, bushings, and explosion
vents. Each component has a specific function to ensure electrical insulation,
temperature regulation, and protection during abnormal conditions.

One of the most important parts of our technical learning was transformer
testing. We observed and noted the following standard tests:

 Insulation Resistance (IR) Test to assess the health of insulation between

windings and earth
 Direct Current Resistance (DCR) Test to detect any internal faults or loose
connections in windings
 Voltage Ratio Test to confirm that the transformation ratio matches the
design specifications
 Magnetic Balance Test to ensure magnetic symmetry across phases
 Vector Group Test to verify the transformer’s phase displacement and
configuration (e.g., Dyn11)
24
  Breakdown Voltage (BDV) Test of transformer oil to evaluate its dielectric
strength
 Tan Delta Test to assess insulation aging and dielectric losses
 Earth Resistance Test to verify proper earthing and personnel safety

In addition, we learned about routine and periodic maintenance schedules

such as daily oil level checks, breather condition, fortnightly and monthly
inspections of OLTC and fans, and half-yearly/annual testing and oil quality
analysis.

Through this internship, we developed a better understanding of real-world

power system equipment, safety standards, electrical diagnostics, and testing
instruments. This hands-on exposure has greatly enhanced our practical skills and
made us more confident in interpreting transformer behavior, identifying faults, and
applying classroom theory to actual industrial systems.

4.2 THE IMPORTANT TRANSFORMERS PROTECTIONS

4.2.1 OVER CURRENT/ EARTH FAULT PROTECTION

The current magnitude relays – or over current relays respond to the

magnitude of their input current, and operate to trip whenever the current
magnitude exceeds a certain value which is adjustable. A typical induction disc
over current relay will have its own characteristics. If the current exceeds
percentage of the set value ( about 105%), the disc may start moving. However
the relay contacts will make only when the current is about 120 to 130%.
Depending upon the characteristics, the operating tie decreases with increase in
current.

The relay will have current setting, time level setting and instantaneous
setting in some cases.

4.2.2 DIFFERENTIAL PROTECTION

The type of protection used for power transformers depends upon the size,
voltage, rating, and the nature of their application.

25
 For small transformer (smaller than about 2 MVA) protection with fuels may
be adequate whereas for transformers of greater than 10MVA Capacity (T-29)
differential relays with harmonic restraint may be used.

Differential protection is based on the comparison of currents on the two

sides of the parts of the installation to be protected. The protected zone, is
between the current transformers on two sides.

4.2.3 OVER – FLUXING PROTECTION

In the case of generator transformers or unit auxiliary transformers, the over

fluxing occurs if excitation is applied to the field before attaining full synchronous
speed or during under-speed or during under-speed operation. In the case of
feeder transformer, over fluxing occurs when there is a system under frequency.

The maximum flux density(Bm) is proportional to the ratio of voltage and

frequency (v/f). In short, over-voltage or under-frequency operation causes over
fluxing. At higher flux density, the core joint gets saturated. A flux then passes
through core bolts. Core bolt insulation gets damaged with consequent failure of
core. Over fluxing is sensed by v/f relay. It may be connected alarm and/or trip
circuit.

4.2.4 RESTRICTED EARTH FAULT PROTECTION AND NCT OPERATED

EARTH FAULT PROTECTION
The transformer can be protected from earth faults by means of residually
connected CT’s (With two overload and earth fault relay scheme, or three over
load and one earth fault relay scheme). If one of the windings are star
connected earthed neutral, earth fault rely connected across neutral CT may be
used.
As the earth fault relay connected in residual connection are across
neutral CT (NCT) has unlimited zone of protection, discrimination with respect to
other earth fault relays is necessary. So except in the case of mining
installations, where limitation of earth fault current is a saturator requirements,
the NCT operated earth fault relay is used for back up protect

26
4.3 TRANSFORMER MAINTENANCE TESTINGS
The following tests are carried out in practice for maintenance purpose
 Insulation resistance Test.
 Direct Current Resistance Test.
 Voltage Ratio Test.
 Magnetic Balance Test.
 Vector Group Test.

4.3.1 INSULATION RESISTANCE TEST

This is done using a motor-operated or hand-operated megger at an

appropriate voltage level. For a transformer. Normally two values are
measured at 15th and 60th seconds after applying megger voltage. The ratio
of megger values at 60th sec to 15th sec is called the absorption factor
which should be greater than 1.3 for a healthy transformer.
The insulation values are measured between.
1-HT side - Earth
2-LT side - Earth.
3-Across HT & LT

Insulation tests for determining the insulation resistance are carried

out between windings between copper and core, and between the core
clamping bolts and the core.

27
 Fig. 4.1 : IR Test Kit – Measures insulation resistance of windings
Fig. 4.1 shows the Insulation Resistance (IR) Test Kit, commonly
known as a megger. It is used to measure the insulation resistance between
transformer windings and earth. This test helps assess the condition of
insulation and detect moisture or deterioration in the winding system.

4.3.2 DIRECT CURRENT RESISTANCE TEST

To check the healthiness of a transformer winding. direct current

winding resistance measurement is one, Voltmeter Ammeter method is a
reliable method. By applying Ohms law the resistance is calculated and
compared with the test records.The measurement is carried out at all taps.
The deviation from the test certificate value [with necessary corrections for
temperature] up to a maximum of 2% is permissible. This test not only
checks the winding but also the tap changer. The voltmeter is to be
connected only after the D.C. current becomes steady It shall be
disconnected immediately after measuring switching off the battery supply.
The measurement is made at a known temperature.

Fig. 4.2 : DCR Test Kit – Checks winding resistance for faults
Fig. 4.2 shows the Direct Current Resistance (DCR) Test Kit, which is
used to measure the resistance of transformer windings. This test helps
identify issues like loose connections, shorted turns, or uneven winding
resistance. Accurate DCR readings are essential for evaluating transformer
health and efficiency.
4.3.3 RATIO TEST

The direct measurement of voltage ratio by the voltmeter is feasible if

the voltages are reasonably low. The ratio test is to be performed on all taps.
The voltage ratio can be found regarding a standard transformer of the same
nominal ratio. The HV sides are connected in parallel to the supply: and a
voltmeter is connected to read the voltage difference between the test and

28
standard LV windings. Assembled transformers may be checked on a ratio-
meter, which is essentially a potential divider excited from the same supply
as the transformer under test, and subdivided to read the LV voltage in
terms of the HV Balance is obtained by connecting the ratio-meter tapping to
the LV winding through an ammeter and adjusting the former until the
current is Zero. Phase: angle difference between primary and secondary
voltages can also be measured with this instrument. As per Indian
standards, the maximum permissible ratio error is 0.5% for any tap
regarding the name plate ratio.

Fig. 4.3 : Ratio Test Kit – Verifies transformer voltage transformation

ratio.
Fig. 4.3 shows the Ratio Test Kit, which is used to verify the voltage
transformation ratio between the high-voltage and low-voltage windings of a
transformer. It ensures the transformer is functioning as per its design
specifications. Deviations in the ratio can indicate internal faults or winding
issues.

4.3.4 MAGNETIC BALANCE TEST

METHOD I :
This test is done to check the healthiness of the magnetic
circuit. The center limb winding is energized with a certain voltage and all
secondary winding voltages are measured. The voltages measured on the
center limb winding will follow the ratio of transformation whereas the
secondary voltage measured on the other limb windings should be half of
the center limb voltage (Secondary).
METHOD II :

29
 If any one of the winding is star connected with brought cut
neutral, a low voltage is applied between middle phase to neutral. The
voltages measured between the other two phases and neutral of the winding
shall be 50 of the applied voltage.

Fig. 4.4 : Magnetic Balance Test – Checks core symmetry and winding
faults
Fig. 4.4 shows the Magnetic Balance Test setup, which is used to
detect abnormalities in the magnetic circuit of a transformer. By energizing
one phase and measuring induced voltages in the other phases, this test
helps identify issues like shorted turns or core displacement. It is especially
useful for diagnosing winding symmetry.

4.3.5 VECTOR GROUP TEST

The relative displacement of the vector regarding the corresponding

HV Vector expressed in the number configuration is known as the vector
group. ex. DY11.
D - stands for HV winding connection delta
Y - stands for the LV winding connection star
N - stands for the brought out neutral of star and
11 - stands for the clock number configuration.
i.e.: LV vector is at 11 'o'clock position regarding the corresponding
HV vector (ie) LV vector loading the corresponding HV vector 30 degrees).
Various vector groups are available. For operating the transformers in
parallel the vector group configuration is to be identical. The vector group

30
Drawn with the measured value will be as follows
VBb = VCb
VCc < VBc

Fig. 4.5 : Vector Group Test – Confirms winding configuration and phase
displacement
Fig. 4.5 shows the Vector Group Test setup, which is used to
determine the phase displacement and winding configuration (e.g., Dyn11)
of a transformer. This test confirms the correct vector relationship between
the high-voltage and low-voltage windings. It ensures compatibility during
parallel operation with other transformers.

4.3.6 DIELECTRIC STRENGTH TEST

An increasing AC voltage of rated frequency is applied to the

electrodes which are immersed in the testing oil (with the gap of 2.5 mm),
approximately at the rate of 2 kV/Sec, starting from zero up to the value
which produces breakdown. The test kit will have provision for automatic
switching off of the supply voltage within 0.02 seconds. The test shall be
repeated six times on the same cell filling and the arithmetic mean of the
results is noted as the electric strength or BDV (Break Down Voltage) of the
oil under test. The test shall be conducted in a dry place free from dust and
voltage applied every time after the disappearance of any air bubbles. The
time intervals shall be five minutes if the disappearance of the air bubble
cannot be observed.

31
Fig. 4.6 : Dielectric Strength Test – Measures insulating strength of
transformer oil
Fig. 4.6 shows the Dielectric Strength Test setup, commonly known as
the BDV (Breakdown Voltage) test. This test helps detect moisture,
contamination, or aging in the oil, ensuring reliable insulation performance.

4.4 MAINTENANCE OF LARGE TRANSFORMER

The objective of efficient maintenance are achieved through the

following forms of maintenance:
A. Routine checks which are to be done daily, fortnightly monthly etc., by
operation and maintenance groups.
B. Periodical tests and maintenance to ensure that the transformer is in fit
condition by maintenance and testing groups
C. Pre-starting tests after an idle period by maintenance and testing groups
D. Major overhaul.
E. Broad details of above maintenance schedule are listed below, followed
up by details checks or tests to made for various items.

4.5 DETAILS OF ROUTINE CHECKS

4.5.1 DAILY CHECKS

 Condition of silicon gel
 Condition of the explosion diaphragm
 Oil level of conservator and bushings
 Absence of leakage of oil
 Maximum and minimum temperature condition of the oil every day

32
  The availability of water in the fire hydrants provided near the
transformer and ensure that the fire hydrants are ready for use.

4.5.2 FORTNIGHTLY CHECKS

 Circulation of oil in radiators
 Condition of neutral connection and earth strip connection.
 Automation cutting in of reserve supply for fan motors and oil pumps.
 Automation starting of reserve banks for failure of the bank where
provided.
 The tightness of fixing bolts of the fan motor base.
4.5.3 MONTHLY CHECKS

 Contacts of the vapor pressure thermometer for high temperature

annunciation and automatic starting of the reserve fan bank where
provided.
 Inspection and cleaning of breather.
 On load tap charger gear mechanism for proper operation.

4.6 PERIODICAL TESTS AND MAINTENANACE

4.6.1 HALF YEARLY TEST AND MAINTENANCE

 B.D.V. of tank oil.

 Dielectric power loss angle (tan delta)of the tank oil.
 Insulation resistance of transformer winding.
 B.D.V. of bushing oil.
 Tan Delta (dielectric loss) angle of bushing oil.
 Checking of earth resistance of neutral earths and transformer and
lightning arrestor earths.
 Cleaning of bushings and applying silicon grease.
 Checking of oil in the hydraulics seal of the bushings.
 Wherever provided the on load tap changer is to be examined, the
contacts cleaned and the oil tested and changed if necessary.

4.6.2 ANNUAL TESTS AND MAINTENACE

 Complete chemical analysis of oil.

33
  IR value and absorption co-efficient of the windings wih jumpers
disconnected.
 Tan delta (dielectric loss angle) of transformer winding.
 Tan delta of bushings.
 Checking of Buchhloz relay for proper functioning.
 Checking IR values of all control and motor cables
 Ratio test.
 Checking of radiators and repairing.
 Overhaul of pumps and motors where provided.
 Inspection of bushing gaskets for leaks.

4.7 PRE-STARTING TESTS AND CHECKS AFTR AN IDLE PERIOD OF ONE

MONTH OR MORE

Measuring the IR value of the windings with jumpers and bus-ducts

connected.
B.D.V. of transformer oil.
Checking of the general condition of the transformer.

4.8 MAJOR OVERHAUL

The manufacture have recommended that the major overhaul has to

be done once in 3 to 5 years. This appears to be too short period for the
overhaul of power transformer of large capacity. The Electricity Board
manual recommends a period of ten years for transformers of ratings 3MVA
and above. Hence it is recommended that high capacity transformer should
be taken out for major overhaul after 6 years of first commissioning.
Subsequently the transformers can be taken out for major overhaul
after every 7 to 8 years. Afer major overhaul the transformer is to be treated
for test purpose as a newly commissioned transformer and all the tests
specified for commissioning a new transformer should be carried out.

34
 CHAPTER – 5

CONCLUSIONS

5.1 SKILLS GAINED

During the two-week industrial training at NLC India Limited (Mine-II

Substation), I gained a wide range of technical and personal skills that significantly
enhanced my growth as an engineering student. The hands-on exposure to
transformer construction, testing methods, substation equipment, and
maintenance practices gave me practical clarity on topics that were previously
understood only through textbooks.
I learned how to interpret real transformer nameplates, operate standard
testing equipment like the Megger, BDV tester, and Ratio Meter, and observe how
a 230 kV/11 kV substation is operated and maintained. Soft skills such as
teamwork, workplace discipline, and safety compliance were also improved
through our daily interactions with experienced engineers and fellow interns.
Moreover, interacting in a professional environment helped me develop better
communication, note-taking, and observation skills—key elements required in real-
world engineering careers.

5.2 CAREER ALIGNMENT

This internship reaffirmed my interest in the field of Electrical Power

Systems, especially in the areas of high-voltage equipment and substation

35
maintenance. The experience helped bridge the gap between academic
knowledge and industrial applications. Concepts like vector group testing,
insulation diagnostics, and fault protection systems that I previously found abstract
are now more relatable and easier to understand.
The practical exposure also gave me a clearer understanding of the roles
and responsibilities of electrical engineers in substation operations. It has inspired
me to explore further studies or certifications in power systems, SCADA
monitoring, and electrical safety. This experience strongly aligns with my career
aspiration to work in core electrical engineering fields such as transmission
utilities, power generation stations, or industrial automation sectors.
5.3 RECOMMENDATIONS
Based on my internship experience, I have the following recommendations
for future trainees and organizers:

 Interns should be encouraged to actively interact with field engineers and

ask questions during observations to enhance their understanding.
 A short orientation at the beginning explaining the daily substation
operations would help new trainees feel more prepared and engaged.
 If possible, allowing interns to assist in simple testing or maintenance
procedures under supervision would provide more hands-on learning.
 Academic institutions should integrate practical transformer and substation
simulations in labs so that students feel confident before visiting real-world
substations.
I would also like to express my sincere gratitude to NLCIL’s Learning &
Development Cell and the engineer mentors who supported and guided us. Their
willingness to share knowledge and involve us in field activities helped make this
internship both educational and inspiring.

36
 REFERENCES

[1] Bimbhra, P. S., "Electrical Machinery", Khanna Publishers, 7th Edition, 2011.
[2] Chakrabarti, A., Soni, M. L., Gupta, P. V., & Bhatnagar, U. S., "A Textbook on
Power System Engineering", Dhanpat Rai & Co., Revised Edition, 2008.
[3] Deshpande, M. V., "Elements of Electrical Power Station Design", PHI Learning
Pvt. Ltd., Reprint Edition, 2010.
[4] Glover, J. D., Sarma, M. S., & Overbye, T. J., "Power System Analysis and
Design", Cengage Learning, 5th Edition, 2011.
[5] Gupta, B. R., "Power System Analysis and Design", S. Chand Publications, 6th
Edition, 2015.
[6] Gupta, J. B., "A Course in Power Systems", S.K. Kataria & Sons, 17th Edition,
2013.
[7] Kulkarni, S. V., & Khaparde, S. A., "Transformer Engineering: Design,
Technology, and Diagnostics", CRC Press, 1st Edition, 2004.
[8] McDonald, J. D., "Electric Power Substations Engineering", CRC Press, 3rd
Edition, 2012.
[9] Nagrath, I. J., & Kothari, D. P., "Power System Engineering", McGraw Hill
Education, 2nd Edition, 2011.
[10] Theraja, B. L., & Theraja, A. K., "A Textbook of Electrical Technology
(Vol. II: AC & DC Machines)", S. Chand Publications, 23rd Edition, 2008.

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