Industrial Training Report

Chapter 1
Introduction to Company
I completed my industrial training in transformer manufacturing name as Power
Engineers Company, Gokul Shirgaon Dist. Kolhapur. This company established in 1977,
as proprietary concern by Shri. Mahadev Dinker Kane B.Sc ,B.E (Elec.).
In 1978-79, as activity concerned mainly with the Rewinding and Repairs of
Distribution Transformers has been taken up. Power Engineers set their own work
shop, in a hired accommodation in Kolhapur with all basic tools and plants. In 1983,
another activity of Service Engineering with Medium High Vacuum transformer oil
filtration mobile plant has been added. Several transformers, pertaining to Major Industrial
and agricultural L.I.S. schemes etc. in almost all the adjacent Districts, have been services,
erected and commissioned, in 11KV,33KV,110KV and 220KV EHV sub-stations. M/S.
Power Engineers started the regular work of Manufacturing and Repairs of distribution
Transformer and have manufactured /repaired several transformers from 63 KVA to 5
MVA. The number of manufactured and repaired transformer is, since then, transformer
has become 150 Nos. increasing every year.

1.1 Area: a) 12000 Sq.ft blocked and enclosed permanently built up shed.
b) 720Sq.ft Mezzanine floor office.
c) 3500Sq.ft open area for unloading stacking etc.

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Chapter 2
Company Production
Company produces the Power and Distribution transformer up to 10 MVA, and
maintenance of transformer.

2.1 Distribution Transformer

Just like the transformers in the Great Barrington system, any transformer that
takes voltage from a primary distribution circuit and steps down or reduces it to a
secondary distribution circuit or a consumers service circuit is a distribution transformer.
Although many industry standards tend to limit this definition by KVA rating (e.g., 5 to
500 KVA), distribution transformers can have lower ratings and can have ratings of 5000
KVA or even higher, so the use of KVA ratings to define transformer types is being
disheartened.

Fig.2.1 Distribution Transformer

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2.2 Power transformer

production of electrical power in low voltage level is very much cost effective.
Hence electrical power is generated in low voltage level theoretically, this law voltage
level of a power is greater than before, the electric current of the power is reduced which
causes drop in

losses in the system, reduction in cross section area of the conductor

i.e. reduction i.e. reduction in capital cost of system and it also improves the voltage
regulation of the system. Because of these, low level power must be stepped up for
efficient electrical power transmission. This is done by step up transformer at the sending
side of the power system network as the high voltage power may not be distributed to the
consumers directly, this must be stepped down transformer. These are uses of electrical
power transmission in the electrical power system.

Fig 2.2. Power transformer

2.3 Maintenance of transformer

To preserve the transformer in perfect operating conditions, keep in mind the
earlier items, also about the routine operation and not forgetting to give the proper
treatment when some change in the service conditions is noted. It is necessary also to deenergize the transformer regularly and conduct a meticulous inspection.
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With this routine and with regular inspection, the degree of deterioration will be
minimized. Since a transformer is made of many parts, such as the insulating oil, the
cooling equipment, etc. must be checked permanently. Oil in addition to serving as
insulating means serves to transfer the heat generated in the windings and the core toward
the walls of the tank and the radiators. Because of this, it is required that it complies with
the following characteristics:
High dielectric breakdown
Low viscosity
Well refined and free of materials that they may corrode the metallic parts
Be free of moisture and polar ionic or colloidal contaminants
To have a low pour point
Low flash point.
The manufacturing techniques for transformers and their reliability have been
improved to such degree that the internal inspection is almost unnecessary; currently the
maintenance is limited almost exclusively to the maintenance of the oil to prevent its
deterioration.

Chapter 3
Electrical Machines in the Company
3.1Machinery:a. Coil winding machine (Round conductor)
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b. Coil winding machine (Strip conductor) suitable for transformer up 10 MVA
c. Cutting edge for press boards and insulating papers
d. Auto controlled, electrically heated hot air circulation ovens 9 KW suitable for jobs
up to 10 MVA
e. Welding machine

3.2 Other Equipments:a. Bench grinder, Portable grinder & drilling machine, blower, portable drill etc.
b. Brazing & cutting gas set.
c. Painting compressor with spray gun & attachment
d. Chucks drills & taps, calipers, micrometer, punching etc.
e. Heavy Duty shifting 4-wheeler trellis, Handling tools, plants, wire, Ropes slings,
hammers Pipe Wrenches and all sundry Tools-kits.

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3.3 Testing Instrument:

Sr. no

Description

Qty.

Specification/Capacity

Dimmer stat

200 Amps, 3 phase

High voltage

80 KV, 250 mA.

testing trans.
3

D.V.T.F.

75 KVA

Booster

1000 KVA, 500 KVA (multi ratio)

Transformer
5

Turns Ratio Meter

Winding

1:300, SEV make

1

Prestige make

Muggers

Motwane Make

5000 Volts 500

Wacco make

Resistance Meter
7

5000 Volts
2500 Volts
1000 Volts
8

C.T

Of various capacities

P.T

Of various capacities

10

Voltmeter

0-600 V, 0.5 class

11

Ammeter

0-10-20 Amp, 0.5 class

12

Wattmeter

LPF, 150-300-600 Volts, 5/10Amp.

13

Micro-ohm meter

0-2 k ohm

14

Oil test set

0-100 KV, 0-120 KV&0-60 KV

15

Digital loss

In house Development

8X

measurement panel
16

Analog millimeters

Table 3.1 Testing Instruments

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Chapter 4
Construction
The transformer is very simple in construction and it consists of magnetic circuit
linking with two windings. The main parts of transformer are
1. Design criteria
2. Core construction.
3. Winding section.
4. Conductor Insulation.
5. Conductor Joining
6. Transformer tank.
7. Conservator tank.
8. Breather.
9. Buchholz relay

4.1 Design Criteria:

1. The transformers shall be installed in hot, humid tropical atmosphere. All
equipment Accessories and wiring shall be provided with tropical finish to prevent
fungus growth.
2. The transformers shall be capable of continuous operation of rated output under the
operating conditions of voltage and frequency variations as per statutory limits
governed by relevant Indian Standard and Electricity Act-2003 and its amendments
in force.
3. The transformer shall conform to best engineering practice.
4. The design material construction shall be such that to secure reliability, economy,
safe and convenient operation and shall include all specified or unspecified
incidental items Necessary for similar equipment for convenient working in every
respect.
5. The transformers shall be capable of withstanding the short circuit stresses due to
terminal fault between phase to phase and phase to ground on one winding with
full voltage Maintained on the other windings for a minimum period of three
seconds.

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6. The transformers shall be free from annoying hum or vibration. The design shall be
such as not to cause any undesirable interference with radio or communication
circuits.
7. Atmospheric Condition: The equipment offered shall be suitable for continuous
satisfactory operation in following prevailing climatic conditions.

4.2 Cores construction:Generally, the name associated with the construction of a transformer is dependent
upon how the primary and secondary windings are wound around the central laminated
steel core. The two most common and basic designs of transformer construction are
the Closed-core Transformer and the Shell-core Transformer.
In the closed-core type (core form) transformer, the primary and secondary
windings are wound outside and surround the core ring. In the shell type (shell form)
transformer, the primary and secondary windings pass inside the steel magnetic circuit
(core) which forms a shell around the windings as shown below.

Fig.4.1 Core Construction

4.3 Windings section:Mainly there are two types of winding are there one is HV winding and another is
LV winding. For windings are frequently used as low-voltage windings. In this form of
construction the winding turn, of copper or aluminum foil, occupies the full width of the
layer. This is wound around a plain mandrel, with intermediate layers of paper insulation,
to form the required total number of turns for the winding. Strips of the conductor material

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are welded or brazed along the edge of the foil at the start and finish to form the winding.
Any slight bulge that this creates in the section of the winding is of no consequence.
A complete HV winding will then be made up of perhaps 6 or 8 coils arranged
axially along the length of the winding and connected in series. Crossover coils are easier
to dry out than full length multilayer windings since they have a short axial length and, by
subdividing the winding into a number of sections, the volts within each section are only a
fraction of the phase volts, thus distributing this evenly along the leg. For this reason this
form of construction is likely to be used for the higher voltage class of HV winding, for
example at 22 or 33 KV, where a simple layer construction would not provide the
necessary clearance distances. Continuous disc windings are, of course, used for any highvoltage winding which has a large enough current to justify the use of a rectangular
conductor. At 11 KV, this probably means a rating of about 750 KVA, three phases and
above would have a disc wound HV winding. At 3.3 KV disc windings will probably be
used for ratings of 250 KVA, three phases and above. Because of their intrinsically greater
mechanical strength, disc windings would be preferred for any transformer known to have
a duty for frequent starting of large motors or other such frequent current surges. Pressure
for much of the innovation introduced into distribution transformers has come from the
competition within this sector of the industry.

Fig. 4.2 Winding of Transformer

Conductors for low-voltage windings were originally made from small rectangular
copper bars, referred to as strap. Higher ratings could require as many as 16 of these
strap conductors in parallel to make one winding having the needed cross section. A
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substantial improvement was gained by using copper strip, which could be much thinner
than strap but with the same width as the coil itself. In the early 1960s, instability in the
copper market encouraged the use of aluminum strip conductor. The use of aluminum
round wire in the primary windings followed in the early 1970s (Palmer, 1983).
Today, both aluminum and copper conductors are used in distribution
transformers, and the choice is largely dictated by economics. Round wire separated by
paper insulation between layers has several disadvantages. The wire tends to gutter, that
is, to fall into the troughs in the layer below. Also, the contact between the wire and paper
occurs only along two lines on either side of the conductor. This is a significant biased vantage when an adhesive is used to bind the wire and paper together. To prevent these
problems, manufacturers often flatten the wire into an oval or rectangular shape in the
process of winding the coil. This allows more conductors to be wound into a given size of
coil and improves the mechanical and electrical integrity of the coil.

4.4 Conductor Insulation:The most common insulation today for high-voltage windings is an enamel coating
on the wire, with craft paper used between layers. Low-voltage strip can be bare with
paper insulation between layers. The use of paper wrapping on strap conductor is slowly
being replaced by synthetic polymer coatings or wrapping with synthetic cloth. For special
applications, synthetic paper such as DuPonts Nomex1 can be used in place of craft
paper to permit higher continuous operating temperatures within the transformer coils.
.4.5 Conductor joining:The introduction of aluminum wire, strap, and strip conductors and enamel
coatings presented a number of challenges to distribution transformer manufacturers.
Aluminum spontaneously forms an insulating oxide coating when exposed to air. This
oxide coating must be removed or avoided whenever an electrical connection is desired.
Also, electrical-conductor grades of aluminum are quite soft and are subject to cold flow
and differential expansion problems when mechanical clamping is attempted. Some
methods of splicing aluminum wires include soldering or crimping with special crimps
that penetrate enamel and oxide coatings and seal out oxygen at the contact areas.
Aluminum strap or strip conductors can be TIG (tungsten inert gas)-welded.

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4.6 Tank :
The transformer tank and cover shall be fabricated from robust M.S. plate steel
without pitting and shall have adequate thickness (Top cover 6 mm min., side plates 5 mm
min., Bottom plate 6 mm min.) with either external cooling tubes or radiators as per
purchasers requirement. The tank and cover shall be of welded construction. All seams shall
be welded and where practicable they shall be double welded. All edges shall be double
welded. The tank wall shall be reinforced by stiffener to ensure rigidity, so that it can
withstand without any deformation the mechanical shock during transportation.
Detachable radiators shall be provided. The shut off valves for radiators should be
supplied if required by purchaser. All removable covers shall be provided with weatherproof,
hot oil resistant, resilient gaskets. The design shall be such as to prevent any leakage of water
into or oil from the tank.
The tank shall be subjected to a pressure test of 0.35 kg/cm2 with hot oil for 12 hours
when the transformer is complete with all fittings. During the test average oil temperature
shall be maintained at 45C above Ambient temperature throughout test period by circulating
suitable current in H.V. winding and short circuiting L.V. winding. There shall be no leakage
of oil during or after the test. Also there shall be no deflection at all when the pressure is
removed. The purchasers representative may be present during these tests for which
advance intimation shall be given. Otherwise, test Certificate shall be produced in triplicate
before dispatching the units. The top cover of the tank shall be suitably sloped to facilitate
water drain off and shall be so designed as to facilitate lifting of the same, in case required,
with minimum disconnection of pipe work and accessories. Air release plugs shall be
provided on main tank top cover to cover entire area suitably.

4.7 Conservator tank:

Conservator tank consists of oil level which depends on the operation of the
transformer. The oil expands in summer with the increase in load and the oil contracts with
decrease of the load. Conservator is a small auxiliary oil tank that may be mounted above the
transformer and connected to the main tank by a pipe. Its main function is to keep the main
tank of the transformer completely filled with the oil in all circumstances. When the oil in
the tank contracts then the conservator gives the oil to maintain the oil level in the tank.
When the oil in the tank expands then the conservator takes the oil.

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Fig.4.3 Conservator Tank

4.8 Breather:A transformer breather is an accessory of an oil filled type transformer which is
attached into the oil conservator tank; this serves as the breathing point of the unit, that when
the insulating oil of the transformer gets heated up, it expands and goes back to the
conservator tank and subsequently pushes the dry air out of the conservator tank through the
breather which is filled with silica gel, when the oil cools down, it retracts and sucks fresh air
from the atmosphere through the breather and from this point, the silica gel dries up the air
that goes back in to the conservator tank.

Fig.4.4 Breather

4.9 Buchhloz relay:Buchholz relay is a gas- actuated relay installed in oil-immersed transformers for
protection against all kind of faults. It is used to gives an alarm in case of slow developing
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faults or incipient faults in the transformer and to disconnect the transformer from the supply
in the event of severe internal faults. It is installed in the pipe between the conservator and
main tank as shown in fig11 below. This relay is used in oil-immersed transformers of rating
above 750 KVA.

4.10 Oil:
The necessary quantity of new transformer oil according to IS: 335 shall be supplied
& filled in the transformer tank up to a height above the minimum filling mark of
conservator tank. The Supplier shall furnish the relevant technical particulars and test
certificates of the oil supplied. An additional 10% of the total quantity of oil required shall be
supplied loose along with the transformer. Leakage of Oil: Suitable approved type of
material such as Neoprene of RC 70 C grade which has an oil proof agent, as specified in
IS: 1866 shall be provided at all joints to prevent leakage of oil during continued operation
or during transportation.

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Chapter 5
Testing of Transformers
The structure of the circuit equivalent of a practical transformer is developed earlier.
The performance parameters of interest can be obtained by solving that circuit for any load
Conditions. The equivalent circuit parameters are available to the designer of the
transformers from the various expressions that he uses for designing the transformers. But
for a user these are not available most of the times. Also when a transformer is rewound with
different primary and secondary windings the equivalent circuit also changes. In order to get
the equivalent circuit parameters test methods are heavily depended upon. From the analysis
of the equivalent circuit one can determine the electrical parameters. But if the temperature
rise of the transformer is required, then test method is the most dependable one. There are
several tests that can be done on the transformer; however a few common ones are discussed
here.

5.1 Winding resistance test:This is nothing but the resistance measurement of the windings by applying a small d.c
voltage to the winding and measuring the current through the same. The ratio gives the
winding resistance, more commonly feasible with high voltage windings. For low voltage
windings a resistance-bridge method can be used. From the d.c resistance one can get the a.c.
resistance by applying skin effect corrections.

5.2 Polarity Test:

This is needed for identifying the primary and secondary phasor polarities. It is a
must for poly phase connections. Both a.c. and d.c methods can be used for detecting the
polarities of the induced emfs. The dot method discussed earlier is used to indicate the
polarities. The transformer is connected to a low voltage a.c. source with the connections
made as shown in the fig. 18(a). A supply voltage Vs is applied to the primary and the
readings of the voltmeters V1, V2 and V3 are noted. V1 : V2 gives the turns ratio. If V3
reads V1V2 then assumed dot locations are correct (for the connection shown). The
beginning and end of the primary and secondary may then be marked by A1 A2 and a1
a2 respectively. If the voltage rises from A1 to A2 in the primary, at any instant it does
so from a1 to a2 in the secondary. If more secondary terminals are present due to taps
taken from the windings they can be labeled as a3, a4, a5, a6. It is the voltage rising from
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smaller number towards larger ones in each winding. The same thing holds well if more
secondaries are present.

5.3 Open circuit test:

As the name suggests, the secondary is kept open circuited and nominal value of
the input voltage is applied to the primary winding and the input current and power are
measured. In Fig. V, A, W are the voltmeter, ammeter and wattmeter respectively. Let
these meters read V1, I0 and W0 respectively. Fig. shows the equivalent circuit of the
transformer under this test. The no load current at rated voltage is less than 1 percent of
nominal current and hence the loss and drop that take place in primary impedance r1 +jxl1
to the no load current I0 is negligible. The active component Ic of the no load current I0
represents the core losses and reactive current Im is the current needed for the
magnetization. Thus the watt meter reading

OR

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5.4 Short Circuit Test:

The purpose of this test is to determine the series branch parameters of the
equivalent circuit of Fig.. As the name suggests, in this test primary applied voltage, the
current and power input are measured keeping the secondary terminals short circuited. Let
these values be Vsc, Isc and Wsc respectively. The supply voltage required to circulate
rated current through the transformer is usually very small and is of the order of a few
percent of the nominal voltage. The excitation current which is only 1 percent or less even
at rated voltage becomes negligibly small during this test and hence is neglected.
Therefore Wsc is the sum of the copper losses in primary and secondary put together. The
reactive power consumed is that absorbed by the leakage reactance of the two windings.

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Chapter 6
Fabrication
6.1 Tank Fabrication
Protection of active part of 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 and external fault 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 national / international standersa A
robust skid under base is provided, and guide bar are located inside the tank to secure fix
the core and winding assembly in position and to prevent any movement during
transportation.
Welding is done as per ASME section IX by qualified welders as per approved
WPS and leak test assured 100% leak Profs Seams and maximum mechanical strengths.
During fabrication process, welding quality is assessed by DP test. Complete tank
fabrication is followed by shot blasting process to remove all dust & spatters before
painting.

Fig.6.1 Fabrication of Transformer

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6.2 Painting of transformer

Where large areas of bare metal are to be painted, the specifications written for
cleaning and painting new transformers should address the following
a) All exterior exposed surfaces of ferrous metal work for the transformers shall be
cleaned to base metal by sandblasting or steel grit blatting. After cleaning, the
surfaces shall be given one coat of priming paint followed by two coats of semi gloss
enamel? The exterior surfaces of aluminum metal shall be cleaned by using clean rags
and a solvent (xylol). After cleaning, apply metal conditioner followed by one coat of
zinc dust-zinc oxide primer and two coats of semi gloss enamel. All paint shall be
applied in a workmanlike manner. Surfaces to be painted shall be thoroughly clean
and dry before application of the paint.
b) Coating materials shall conform to the specifications which govern the specific
project or solicitation for which they are to be used.
c) The contractor shall furnish the Government with a certification by the manufacturer,
stating that these materials conform to the requirements of the designated
specifications. The contractor shall be responsible for the accuracy of the certificates.
The certificates must contain in addition, the type, batch, color, quantity, and Bureau
of Reclamation solicitation/specifications numbers under which the material is to be
used. A copy of the purchase order for the materials should be included as well. In the
absence of a written purchase order, a statement that it was a verbal one will suffice.
The Government reserves the right to test materials accepted on certification.

Fig.6.2 Painting of Transformer

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Chapter 7
Conclusion

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