Chapter 1: Introduction

1.1 The Company

Since 1994, S.J. Transformers Rampur are a leading and thoughtful
manufacturer and supplier of power and distribution transformers in Uttar Pradesh.
They have been in the field of quality transformers. This company with its vast
industry experience and expertise has been providing the best range of transformers
with tradition and innovation. All these products are designed and developed under
stringent testing in accordance with the Indian norms. Therefore, the product
possesses several excellent features such as compact design, long life working,
maintenance free and high overload capacity.

1.2 Product range

They are manufacturing and supplying the distribution transformers
(Pole/Ground

mounted) to the Uttar Pradesh Power Corporation Limited. They are

manufacturing power distribution transformers of range from 25kVA to 1000kVA of

Oil Type. They all are developed with the high quality control testing and materials.
Constantly working for technological up gradation and customer satisfaction
in terms of world class quality and services. Their core business philosophy comes
from their commitment to be partners of growth and value additions while meeting
larger issues like energy saving and reaching out for the power needs of the poor and
remotely placed. They at S.J. Transformers produce transformers as per National and
International Standards i.e. Bureau of Indian Standard (BIS) International Electro
technical Institute (IEC), ANSI etc.

Chapter 2: Transformer
2.1 Rationale

Transformer is AC machine which transforms electrical energy from one

circuit to another without changing frequency by the principle of electromagnetic
induction. Since its basic construction requires no moving parts so it is often called a
static transformer and it is a very rugged machine requiring minimum amount of
repair and maintenance. Owing to the lack of rotating parts, there are no friction
losses or winding losses. Further the other losses are very low so the efficiency should
be high. The efficiency varies from 97% to 99%.

2.2 Operating Principle

The action of the transformer is based on the principle that energy may be
efficiently transferred by induction from one set of coils to another by means of
varying magnetic flux, provided that both set of coils are on same magnetic circuit.
The emf are induced by the variation of the magnetic flux with time. It is based on the
Faradays Law of Electromagnetic Induction.

2.3 Power and Distribution Transformers

The term Power Transformer is used to include transformers of large sizes
(250kVA and above) used in generating stations and substation for transforming the
voltage at each end of power transmission line. They may be single phase or three
phase of volage rating of 11/220kVA or higher. The power transformers are designed
to have maximum efficiency at full load (i.e. iron loss to full load copper loss ratio
1:1).
The transformers of rating up to 200kVA are called as distribution transformers.
They are used to step down the high voltage to some standard voltages. In such type
of transformers, the iron loss occurs all time but copper loss occurs only when they
are loaded. Therefore, distribution transformers are designed with iron loss smaller in
comparison with copper loss (say iron loss to full load copper loss ratio 1:3).

Chapter 3: Manufacturing Process of Transformers

3.1 Block Diagram of Manufacturing Process of Transformers

This block diagram shows the steps used in the manufacturing of distribution
transformers:
Core Construction

Winding Construction

Core and Winding Assembly

Moisture Removal
Process

Core fitting in tank

Bushing Connections

Oil Filling

Installing Protection
System
Fig 3.1 Block Diagram

Chapter 4: Core Construction

4.1 Purpose of the Core
3

In an electrical power transformer, there are primary, secondary and may be

tertiary windings. The performance of a transformer mainly depends upon the flux
linkages between these windings. For efficient flux linking between these windings,
one low reluctance magnetic path common to all windings should be provided in the
transformer. This low reluctance magnetic path in transformer is known as core of
tranformer.

4.2 Influence of Diameter of Transformer Core

Let us consider, the diameter of transformer core be D Then, cross-sectional

area of the core,
A=

D2
4

Now, Voltage per turn,

E=4.44 m f =4.44 A Bm f

Where Bm is the maximum flux density of the core.

4.44 D 2 B m f

E is proportional to D2.
Therefore, voltage per turn is increased with increase in diameter of
transformer core. Again if voltage across the winding of transformer is V. Then V =
eN, where N is the number of turns in winding.
If V is constant, e is inversely proportional to N. And hence, D 2 is inversely
proportional to N. So, diameter of the core is increased, the number of turns in the
transformer winding reduced. Reduction of number of turns, reduction in height of the
4

core legs in-spite of reduction of core legs height increased in core diameter, results
increase in overall diameter of magnetic core of transformer. This increased steel
weight ultimately leads to increased core losses in transformer. Increased diameter of
the core leads to increase in the main diameter on the winding. In spite of increased
diameter of the winding turns, reduced number of turns in the windings, leads to less
copper loss in transformer. So, we go on increasing diameter of the transformer core,
losses in the transformer core will be increased but at the same time, load loss or
copper loss in transformer is reduced. On the other hand, if diameter of the core is
decreased, the weight of the steel in the core is reduced; which leads to less core loss
of transformer, but in the same time, this leads to increase in number of turns in the
winding, means increase in copper weight, which leads to extra copper loss in
transformer. So, diameter of the core must be optimized during designing of
transformer core, considering both the aspects.

4.3 Material of Transformer Core

The main problem with transformer core is, its hysteresis loss and eddy
current loss in transformer. Hysteresis loss in transformer mainly depends upon its
core materials. It is found that, a small quantity of silicon alloyed with low carbon
content steel produces material for transformer core, which has low hysteresis loss
and high permeability. Because of increasing demand of power, it is required to
further reduce the core losses and for that, another technique is employed on steel,
which is known as cold rolling. This technique arranges the orientation of grain in
ferromagnetic steel in the direction of rolling. The core steel which has under gone
through both the silicon alloying and cold rolling treatments is commonly known as
CRGOS or Cold Rolled Grain Oriented Silicon Steel. This material is now universally
used for manufacturing transformer core. Although this material has low specific iron
loss but still; it has some disadvantages, like, it is susceptible to increase loss due to
flux flow in direction other than grain orientation and it also susceptible to impaired
performance due to impact of bending and blanking the cutting CRGOS sheet. Both
the surfaces of the sheet are provided with an insulating of oxide coating.

4.4 Optimum Design of Cross Section of Transformer Core

The maximum flux density of CRGO steel is about 1.9 Tesla. Means the steel
becomes saturated at the flux density 1.9 Tesla. One important criteria for the design
of transformer core, is that, it must not be saturated during the transformers normal
operation mode. Voltages of transformer depend upon its total magnetizing flux. Total
magnetizing flux through core is nothing but the product of flux density and cross
sectional area of the core. Hence, flux density of a core can be controlled by adjusting
the cross sectional area of the core during its design.

Fig 4.1 Core Cross Section

The ideal shape of cross-section of a transformer core is circular. For making

perfect circular cross section, each and every successive lamination steel sheet should
be cut in different dimension and size. This is absolutely uneconomical for practical
manufacturing. In reality, manufacturers use different groups or packets of predefined
number of same dimension lamination sheets. The group or packet is a block of
laminated sheets with a predefined optimum height (thickness). The core is an
6

assembly of these blocks in such a successive manner as per their size from core
central line, that it gives an optimum circular shape of the cross-section. Such typical
cross-section is shown in the figure below. Oil ducts are needed for cooling the core.
Cooling ducts are necessary because hot-spot temperature may rise dangerously high
and their number depends on the core diameter and materials that get used for core. In
addition to that, clamp plates made of steel are needed on either sides of the core to
clamp the lamination. The steel sheet lamination blocks, oil ducts, and clamping
plates; all should lie within the peripheral of optimum core circle.
The net sectional area is calculated from the dimensions of various packets and
allowance is made for the space lost between lamination (known as stacking factor)
for which steel sheet of 0.28 mm thickness with insulation coating is approximately
0.96. Area is also deducted for oil ducts. The ratio of net cross sectional area of core
to the gross cross - sectional area inside the imaginary peripheral circle is known as
Utilization factor of transformer core. Increasing numbers of steps improve the
Utilization factor but at the same time, it increases manufacturing cost. Optimum
numbers of steps are between 6 (for smaller diameter) to 15 (larger diameter).

4.5 Manufacturing of Transformer Core

During core manufacturing in factory some factors are taken into consideration,

1.

Reduction in iron loss in transformer and magnetizing current.

2.

Higher reliability.

3.

Lowering material cost and labor cost.

4.

Abatement of noise levels.

Quality checking is necessary at every step of manufacturing to ensure quality
and reliability. The steel sheet must be tested for ensuring the specific core loss or iron
loss values. The lamination should be properly checked and inspected visually, rusty
and bend lamination should be rejected. For reducing the transformer noises, the
lamination should be tightly clamped together and punch holes should be avoided as
far as possible to minimize cross flux iron losses. The air gap at the joint of limbs and
7

yokes should be reduced as much as possible for allowing maximum smooth

conducting paths for magnetizing current.
Thin steel sheets are stacked on one over another. The shape is kept of core
type for distribution transformer (i.e. E+I type). After a certain weight designed for
each type of transformer this process is stopped and after tightening and fitting these
steel laminations on frame, the core is straightened.

Fig 4.2 Core Manufacturing

Chapter 5: Winding Construction

The conducting material used for the windings depends upon the application, but in
all cases the individual turns must be electrically insulated from each other to ensure that the
current travels throughout every turn. For small power and signal transformers, in which
currents are low and the potential difference between adjacent turns is small, the coils are
often wound from enamelled magnet wire, such as Formvar wire. Larger power transformers
operating at high voltages may be wound with copper rectangular strip conductors insulated
by oil-impregnated paper and blocks of pressboard High-frequency transformers operating in
the tens to hundreds of kilohertz often have windings made of braided Litz wire to minimize
the skin-effect and proximity effect losses. Large power transformers use multiple-stranded
conductors as well, since even at low power frequencies non-uniform distribution of current
would otherwise exist in high-current windings. Each strand is individually insulated, and the
strands are arranged so that at certain points in the winding, or throughout the whole winding,
each portion occupies different relative positions in the complete conductor. The transposition
equalizes the current flowing in each strand of the conductor, and reduces eddy current losses

in the winding itself. The stranded conductor is also more flexible than a solid conductor of
similar size, aiding manufacture.
The windings of signal transformers minimize leakage inductance and stray
capacitance to improve high-frequency response. Coils are split into sections, and those
sections interleaved between the sections of the other winding.
Power-frequency transformers may have taps at intermediate points on the winding,
usually on the higher voltage winding side, for voltage adjustment. Taps may be manually
reconnected, or a manual or automatic switch may be provided for changing taps. Automatic
on-load tap changers are used in electric power transmission or distribution, on equipment
such as arc furnace transformers, or for automatic voltage regulators for sensitive loads.
Audio-frequency transformers, used for the distribution of audio to public address
loudspeakers, have taps to allow adjustment of impedance to each speaker. A center-tapped
transformer is often used in the output stage of an audio power amplifier in a push-pull
circuit. Modulation transformers in AM transmitters are very similar.
Dry-type transformer winding insulation systems can be either of standard openwound 'dip-and-bake' construction or of higher quality designs that include vacuum pressure
impregnation (VPI), vacuum pressure encapsulation (VPE), and cast coil encapsulation

processes.

Fig 5.1 LV Coil Winding Machine

Fig 5.2 HV Coil Winding Machine

Chapter 6: Core Assembly and Moisture Removal Process

6.1 Steps of Core and Winding Assembly

Ei core is detached into two parts E and I

.
Fig6.1 Core View

10

Insulation of cotton is wrapped on the limbs of core and then firstly lv and
then hv winding is overlapped together. After that assembly the core frame is
fixed.

Fig 6.2 Core Coil Assembly

6.2 Moisture Removal Process

The core assembly is then kept under oven at 90C for moisture removal for 23hrs.

Fig 6.3 Drying Process

11

After moisture removal, the core and coil assembly is put into the tank by
crane.

Fig 6.4 Core Fitting in Tank

After the whole process oil is filled in the tank after connecting the bushing
connections and placed the lid of the tank.

In the next step painting process takes place.

12

Fig 6.5 Painting Process

After painting has been completed the protection box is attached to the
transformer.

Fig 6.6 Protection Box

Thus the whole process is completed.

Chapter 7: Transformer Testing

7.1 Introduction
For confirming the specifications and performances of an electrical power
transformer, it has to go through numbers of testing procedures. Some tests are done at
manufacturer premises before delivering the transformer. Mainly two types of transformer
testing are done at manufacturer premises- type test of transformer and routine test of
transformer. In addition to that some transformer tests are also carried out at the consumer
site before commissioning and also periodically in regular & emergency basis throughout its
service life.
13

7.2 Type of Testing

(a). Tests done at factory:
1.

Type tests

2.

Routine tests

3.

Special tests

(b). Tests done at site:

1.

Pre-commissioning tests

2.

Periodic/condition monitoring tests

3.

Emergency tests

7.2.1 Type Test of transformer

To prove that the transformer meets customers specifications and design expectations,
the transformer has to go through different testing procedures in manufacturer premises.
Some transformer tests are carried out for confirming the basic design expectation of that
transformer. These tests are done mainly in a prototype unit not in all manufactured units in
a lot. Type test of transformer confirms main and basic design criteria of a production lot.
Type tests of transformer includes
1.

Transformer winding resistance measurement

2.

Transformer ratio test.

3.

Transformer vector group test.

4.

Measurement of impedance voltage/short circuit impedance (principal

tap) and load loss (Short circuit test).

5.

Measurement of no load loss and current (Open circuit test).

6.

Measurement of insulation resistance.

7.

Dielectric tests of transformer.

8.

Temperature rise test of transformer.

9.

Tests on on-load tap-changer.

7.2.2 Routine Test of Transformer

Routine tests of transformer are mainly for confirming operational performance of individual
unit in a production lot. Routine tests are carried out on every unit manufactured. Routine
tests of transformer include
1.

Transformer winding resistance measurement.

14

2.

Transformer ratio test.

3.

Transformer vector group test.

4.

Measurement of impedance voltage/short circuit impedance (principal tap) and load

loss (Short circuit test).

5.

Measurement of no load loss and current (Open circuit test)

6.

Measurement of insulation resistance.

7.

Dielectric tests of transformer.

8.

Tests on on-load tap-changer.

9.

Oil pressure test on transformer to check against leakages past joints and gaskets.

That means Routine tests of transformer include all the type tests except temperature rise and
vacuum tests. The oil pressure test on transformer to check against leakages past joints and
gaskets is included.

7.2.3 Special Test of Transformer

Special tests of transformer is done as per customer requirement to obtain information useful
to the user during operation or maintenance of the transformer. Special Tests of transformer
include:
1.

Dielectric tests.

2.

Measurement of zero-sequence impedance of three-phase transformers

3.

Short-circuit test.

4.

Measurement of acoustic noise level.

5.

Measurement of the harmonics of the no-load current.

6.

Measurement of the power taken by the fans and oil pumps.

7.

Tests on bought out components / accessories such as buchhloz relay, temperature

indicators, pressure relief devices, oil preservation system etc.

7.3 Transformer Winding Resistance Measurement

Transformer winding resistance measurement is carried out to calculate the I2R losses and to
calculate winding temperature at the end of a temperature rise test. It is carried out as a type

15

test as well as routine test. It is also done at site to ensure healthiness of a transformer that is
to check loose connections, broken strands of conductor, high contact resistance in tap
changers, high voltage leads and bushings etc.
There are different methods for measuring of transformer winding, likewise

Current voltage method of measurement of winding resistance.

Bridge method of measurement of winding resistance.
Kelvin bridge method of Measuring Winding Resistance.
Measuring winding resistance by Automatic Winding Resistance Measurement Kit.
Transformer winding resistance measurement shall be carried out at each tap.
The transformer winding resistances can be measured by current voltage method. In

this method of measurement of winding resistance, the test current is injected to the winding
and corresponding voltage drop across the winding is measured.
By applying simple Ohm's law i.e. Rx = V I, one can easily determine the value of
resistance.
Procedure of Current Voltage Method of Measurement of Winding Resistance:
1.

Before measurement the transformer should be kept in OFF condition without

excitation at least for 3 to 4 hours. During this time the winding temperature will become
equal to its oil temperature.

2.

Measurement is done with D.C.

3.

To minimize observation errors, polarity of the core magnetization shall be kept

constant during all resistance readings.

4.

Voltmeter leads shall be independent of the current leads to protect it from high
voltages which may occur during switching on and off the current circuit.

5.

The readings shall be taken after the current and voltage have reached steady state
values. In some cases this may take several minutes depending upon the winding
impedance.

6.

The test current shall not exceed 15% of the rated current of the winding. Large
values may cause inaccuracy by heating the winding and thereby changing its resistance.

7.

For expressing resistance, the corresponding temperature of the winding at the time of
measurement must be mentioned along with resistance value. As we said earlier that
after remaining in switch off condition for 3 to 4 hours, the winding temperature would

16

become equal to oil temperature. The oil temperature at the time of testing is taken as the
average of top oil and bottom oil temperatures of transformer.

Fig 7.1 Star Winding Resistance Measurement

1.

For star connected three phase winding, the resistance per phase would be half of
measured resistance between two line terminals of the transformer.

2.

For delta connected three phase winding, the resistance per phase would be 0.67 times
of measured resistance between two line terminals of the transformer.

3.

This current voltage method of measurement of winding resistance of transformer

should be repeated for each pair of line terminals of winding at every tap position.

Fig 7.2 Delta Winding Resistance Measurement

17

Bridge Method of Measurement of Winding Resistance

Fig 7.3 Kelvin Bridge Winding Resistance Measurement

The main principle of bridge method is based on comparing an unknown resistance

with a known resistance. When currents flowing through the arms of bridge circuit
becomebalanced, the reading of galvanometer shows zero deflection that means at balanced
condition no current will flow through the galvanometer. Very small value of resistance ( in

18

milli-ohms range) can be accurately measured by Kelvin bridge method whereas for higher

Fig 7.4 Kelvin Bridge Winding Resistance Measurement Circuit

value Wheatstone bridge method of resistance measurement is applied. In bridge

method of measurement of winding resistance, the errors is minimized.
The resistance measured by Kelvin bridge,

All other steps to be taken during transformer winding resistance measurement in these
methods are similar to that of current voltage method of measurement of winding resistance
of transformer, except the measuring technique of resistance.

19

Fig 7.5 Wheatstone Winding Resistance Measurement

The resistance measured by Wheatstone bridge,

7.4 Transformer Ratio Test

The performance of a transformer largely depends upon perfection of specific turns or

voltage ratio of transformer. So transformer ratio test is an essential type test of transformer.
This test also performed as routine test of transformer. So for ensuring proper performance of
electrical power transformer, voltage and turn ratio test of transformer one of the vital tests.
The procedure of transformer ratio test is simple. We just apply three phase 415 V
supply to HV winding, with keeping LV winding open. The we measure the induced voltages
at HV and LV terminals of transformer to find out actual voltage ratio of transformer. We
repeat the test for all tap position separately.

7.5 Magnetic Balance Test of Transformer

20

Magnetic balance test of transformer is conducted only on three phase transformers to

check the imbalance in the magnetic circuit.
Procedure of Magnetic Balance Test of Transformer:
1.

First keep the tap changer of transformer in normal position.

2.

Now disconnect the transformer neutral from ground.

3.

Then apply single phase 230 V AC supply across one of the HV winding
terminals and neutral terminal.

4.

Measure the voltage in two other HV terminals in respect of neutral terminal.

5.

Repeat the test for each of the three phases.

In case of auto transformer, magnetic balance test of transformer should be repeated for LV
winding also.
There are three limbs side by side in a core of transformer. One phase winding is wound in
one limb. The voltage induced in different phases depends upon the respective position of the
limb in the core. The voltage induced in different phases of transformer in respect to neutral
terminals given in the table below.

Applied Voltage Sides

Left

Side Central

Phase

Phase

Right
Side
Phase

AN

BN

CN

Voltage applied at left side phase

230V

180V

50V

Voltage applied at central phase

115V

230V

115V

Voltage applied at right side phase

50V

180V

230V

Table 7.1 Magnetic Balance Test Table

7.6 Vector Group Test of Transformer

21

In three phase transformer, it is essential to carry out a vector group test of transformer.
Proper vector grouping in a transformer is an essential criteria for parallel operation of
transformers.
There are several internal connections of three phase transformer are available in
market. These several connections give various magnitudes and phase of the secondary
voltage; the magnitude can be adjusted for parallel operation by suitable choice of turn ratio,
but the phase divergence cannot be compensated. So we have to choose those transformer for
parallel operation whose phase sequence and phase divergence are same. All the transformers
with same vector ground have same phase sequence and phase divergence between primary
and secondary. So before procuring one electrical power transformer, one should ensure the
vector group of the transformer, whether it will be matched with his or her existing system or
not. The vector group test of transformer confirms his or her requirements.
The vector group of transformer is an essential property for successful parallel
operation of transformers. Hence every electrical power transformer must undergo through
vector group test of transformer at factory site for ensuring the customer specified vector
group of transformer. The phase sequence or the order in which the phases reach their
maximum positive voltages, must be identical for two paralleled transformers. Otherwise,
during the cycle, each pair of phases will be short circuited. The several secondary
connections are available in respect of various primary three phase connection in a the three
phase transformer. So for same primary applied three phase voltage there may be different
three phase secondary voltages with various magnitudes and phases for different internal
connection of the transformer. Let's have a discussion in detail by example for better
understanding.
We know that, the primary and secondary coils on any one limb have induced emfs
that are in time-phase. Let's consider two transformers of same number primary turns and the
primary windings are connected in star. The secondary number of turns per phase in both
transformers are also same. But the first transformer has star connected secondary and other
transformer has delta connected secondary. If same voltages are applied in primary of both
transformers, the secondary induced emf in each phase will be in same time-phase with that
of respective primary phase, as because the the primary and secondary coils of same phase
are wound on the same limb in the core of transformer. In first transformer, as the secondary
22

is star connected, the secondary line voltage is 3 times of induced voltage per secondary
phase coil. But in case of second transformer, where secondary is delta connected, the line
voltage is equal to induced voltage per secondary phase coil. If we go through the vector
diagram of secondary line voltages of both transformer, we will easily find that there will be a
clear 30o angular difference between the line voltages of these transformers. Now, if we try to
run these transformers in parallel then there will be a circulating current flows between the
transformers as because there is a phase angle difference between their secondary line
voltages. This phase difference can not be compensated. Thus two sets of connections giving
secondary voltages with a phase displacement can not be intended for parallel operation of
transformers.
The following table gives the connections for which from the view point of phase
sequence and angular divergences, transformer can be operated parallel. According to their
vector relation, all three phase transformers are divided into different vector group of
transformer. All electrical power transformers of a particular vector group can easily be
operated in parallel if they fulfill other condition for parallel operation of transformers.

Group Connection
Yy0

Connection
Dd0

0
(0o)

23

Yd1

Dy1

Yy6

Dd6

Yd11

Dy11

1
( 30o)

6
( 180o)

11
( - 30o)

24

Table 7.2 Vector Group Test

Procedure of Vector Group Test of Transformer:

Fig 7.6 Vector Group Test

Lets have a YNd11 transformer.

1.

Connect neutral point of star connected winding with earth.

2.

Join 1U of HV and 2W of LV together.

3.

Apply 415 V, three phase supply to HV terminals.

4.

Measure voltages between terminals 2U-1N, 2V-1N, 2W-1N, that means voltages
between each LV terminal and HV neutral.

5.

Also measure voltages between terminals 2V-1V, 2W-1W and 2V-1W.

For YNd11 transformer, we will find, 2U-1N > 2V-1N > 2W-1N 2V-1W > 2V-1V or 2W-1W .
The vector group test of transformer for other group can also be done in similar way.

7.7 Insulation Resistance Test or Megger Test of Transformer

25

Insulation resistance test of transformer is essential type test. This test is carried out to ensure
the healthiness of overall insulation system of an electrical power transformer.

Fig 7.7 Megger

Procedure of Insulation Resistance Test of Transformer

1.

First disconnect all the line and neutral terminals of the transformer.

2.

Megger leads to be connected to LV and HV bushing studs to measure

insulation resistance IR value in between the LV and HV windings.

3.

Megger leads to be connected to HV bushing studs and transformer tank earth

point to measure insulation resistance IR value in between the HV windings and earth.

4.

Megger leads to be connected to LV bushing studs and transformer tank earth

point to measure insulation resistance IR value in between the LV windings and earth.

7.8 Dielectric Tests of Transformer (DVDF Test)

Dielectric tests of transformer is one kind of insulation test. This test is performed to
ensure the expected over all insulation strength of transformer. There are several test
performed to ensure the required quality of transformer insulation, dielectric test is one of
26

them. Dielectric tests of transformer is performed in two different steps, first one called
Separate source voltage withstand test of transformer, where a single phase power frequency
voltage of prescribed level, is applied on transformer winding under test for 60 seconds while
the other windings and tank are connected to the earth and it is observed that whether any
failure of insulation occurs or not during the test. Second one is induced voltage test of
Transformer where, three phase voltage, twice of rated secondary voltage is applied to the
secondary winding for 60 second by keeping the primary of the transformer open circuited.
The frequency of the applied voltage should be double of power frequency too. Here also if
no failure of insulation, the test is successful. In addition to dielectric tests of transformer
there are other type test for checking insulation of transformer, such as lightning impulse test,
switching impulse test and partial discharge test.
DVDF (Double voltage and double frequency) test is popular test conducted on the
Transformer before it is commissioned. In this test double the rated voltage and double the
rated frequency is applied to the Transformer under test and observed for its withstand
capability usually for 1 min. Double voltage is applied to test the Transformer withstand
capability for higher voltages which are sometimes occur in the form of lightning surges and
faults on the transformer. But, practically, no transformer is subjected to double the rated
frequency as the frequency variations are not allowed beyond 0.5% by the power supply grid
controlling authority. In such a case, is it essential to test the transformer at 200% i.e. double
the rated frequency conditions?
When alternating electrical source is applied to the primary winding of the
transformer, it draws magnetizing current which produces alternating flux in the core of the
transformer. This flux links both primary and secondary windings and due its alternating
nature EMF is induced across both windings and Erms can be deduced by the equation.
Erms= 4.44mfN volts
Where

Erms is RMS voltage induced

m is maximum flux linked
f is the operating frequency
N is the number of turns in the winding.

As per the above equation, when double the rated voltage is applied while testing
the transformer, without doubling the frequency, the maximum amount of flux linked will
also be doubled as the number of turns is always constant for a particular design. This causes
the abnormal heating of core of the Transformer under test and the magnetizing properties of
the core are disturbed permanently. Hence, to avoid this abnormal heating of the Transformer
27

due to increase in flux, applied frequency will also be doubled along with applied voltage to
test the high voltage with stand capability of the Transformer. Thus the test is named as
Double Voltage Double Frequency test.

6.9 Transformer Oil Testing

Transformer oil, a type of insulating and cooling oil used in transformers and other
electrical equipment, needs to be tested periodically to ensure that it is still fit for purpose.
This is because it tends to deteriorate over time. Testing sequences and procedures are
defined by various international standards, many of them set by ASTM. Testing consists of
measuring breakdown voltage and other physical and chemical properties of samples of the
oil, either in a laboratory or using portable test equipment on site. The transformer oil
(insulation oil) of voltage- and current-transformers fulfills the purpose of insulating as well
as cooling. Thus, the dielectric quality of transformer oil is essential to secure operation of a
transformer.
As transformer oil deteriorates through aging and moisture ingress, transformer oil
should, depending on economics, transformer duty and other factors, be tested periodically.
Power utility companies have a vested interest in periodic oil testing since transformers
represent a large proportion of their total assets. Through such testing, transformers' life can
be substantially increased, thus delaying new investment of replacement transformer assets.
Recently time-consuming testing procedures in test labs have been replaced by on-site oil
testing procedures. There are various manufacturers of portable oil testers. With low weight
devices in the range of 20 to 40 kg, tests up to 100 kV rms can be performed and reported onsite automatically. Some of them are even battery-powered and come with accessories. To
assess the insulating property of dielectric transformer oil, a sample of the transformer oil is
taken and its breakdown voltage is measured. The lower the resulting breakdown voltage, the
poorer the quality of the transformer oil.

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Fig 7.8 Transformer Oil Test Set

The transformer oil is filled in the vessel of the testing device. Two standardcompliant test electrodes with a typical clearance of 2.5 mm are surrounded by the
dielectric oil.

A test voltage is applied to the electrodes and is continuously increased up to the

breakdown voltage with a constant, standard-compliant slew rate of e.g. 2 kV/s.

At a certain voltage level breakdown occurs in an electric arc, leading to a collapse of

the test voltage.

An instant after ignition of the arc, the test voltage is switched off automatically by
the testing device. Ultra fast switch off is highly desirable, as the carbonisation due to the
electric arc must be limited to keep the additional pollution as low as possible.

The transformer oil testing device measures and reports the root mean square value of
the breakdown voltage.

After the transformer oil test is completed, the insulation oil is stirred automatically
and the test sequence is performed repeatedly: typically 5 repetitions, depending on the
standard.

As a result the breakdown voltage is calculated as mean value of the individual

measurements.

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7.10 Open Circuit and Short Circuit Test

These two tests are performed on a transformer to determine
1.

equivalent circuit of transformer

2.

voltage regulation of transformer

3.

efficiency of transformer. The power required for these open circuit test and short
circuit test on transformer is equal to the power loss occurring in the transformer.

7.10.1 Open Circuit Test on Transformer

The connection diagram for open circuit test on transformer is shown in the figure. A
voltmeter, wattmeter, and an ammeter are connected in LV side of the transformer as shown.
The voltage at rated frequency is applied to that LV side with the help of a variac of variable
ratio auto transformer.
The HV side of the transformer is kept open. Now with the help of variac, applied
voltage gets slowly increased until the voltmeter gives reading equal to the rated voltage of
the LV side. After reaching at rated LV side voltage, all three instruments reading (Voltmeter,
Ammeter and Wattmeter readings) are recorded.

Fig 7.9 OC Test

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The ammeter reading gives the no load current Ie. As no load current Ie is quite small
compared to rated current of the transformer, the voltage drops due to this current that can be
taken as negligible. Since, voltmeter reading V1 can be considered equal to secondary
induced voltage of the transformer, the input power during test is indicated by watt-meter
reading. As the transformer is open circuited, there is no output, hence the input power here
consists of core losses in transformer and copper loss in transformer during no load condition.
But as said earlier, the no load current in the transformer is quite small compared to full load
current, so copper loss due to the small no load current can be neglected. Hence, the
wattmeter reading can be taken as equal to core losses in transformer. Let us consider
wattmeter reading is Po.

Where Rm is shunt branch resistance of transformer. If, Zm is shunt branch impedance

of transformer

Therefore,

if

shunt

branch

reactance

of

transformer

is

X m,

These values are referred to the LV side of transformer as because the test is conduced
on LV side of transformer. These values could easily be referred to HV side by multiplying
these values with square of transformation ratio.
Therefore it is seen that the open circuit test on transformer is used to determine core losses
in transformer and parameters of shunt branch of the equivalent circuit of transformer.

7.10.2 Short Circuit Test on Transformer

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The connection diagram for short circuit test on transformer is shown in the figure. A
voltmeter, wattmeter, and an ammeter are connected in HV side of the transformer as shown.
The voltage at rated frequency is applied to that HV side with the help of a variac of variable
ratio auto transformer.
The LV side of the transformer is short circuited. Now with the help of variac applied
voltage is slowly increased until the ammeter gives reading equal to the rated current of the
HV side. After reaching at rated current of HV side, all three instruments reading (Voltmeter,
Ammeter and Watt-meter readings) are recorded. The ammeter reading gives the primary
equivalent of full load current I L. As the voltage applied for full load current in short circuit
test on transformer is quite small compared to the rated primary voltage of the transformer,
the core losses in transformer can be taken as negligible here.

Fig 7.10 SC Test

Lets say, voltmeter reading is Vsc. The input power during test is indicated by wattmeter reading. As the transformer is short circuited, there is no output; hence the input power
here consists of copper losses in transformer. Since, the applied voltage V sc is short circuit
voltage in the transformer and hence it is quite small compared to rated voltage, so core loss
due to the small applied voltage can be neglected. Hence the wattmeter reading can be taken
as equal to copper losses in transformer. Let us consider wattmeter reading is Psc.

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Where Re is equivalent resistance of transformer. If, Ze is equivalent impedance of

transformer.

Therefore, if equivalent reactance of transformer is Xe

These values are referred to the HV side of transformer as because the test is
conduced on HV side of transformer. These values could easily be referred to LV side by
dividing these values with square of transformation ratio.
Therefore it is seen that the short circuit test on transformer is used to determine
copper loss in transformer at full load and parameters of approximate equivalent circuit of
transformer.

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Chapter 8: Transformer Accessories

8.1 Conservator with Drain Plug and Filling hole

This is a cylindrical tank mounted on supporting structure on the roof the transformer
main tank. The main function of conservator tank of transformer is to provide adequate space
for expansion of oil inside the transformer.
When transformer is loaded and when ambient temperature rises, the volume of oil
inside transformer increases. A conservator tank of transformer provides adequate space to
this expanded transformer oil. It also acts as a reservoir for transformer insulating oil. This is
a cylindrical shaped oil container closed from both ends. One large inspection cover is
provided on either side of the container to facilitate maintenance and cleaning inside of the
conservator.
Conservator pipe, i.e. pipe comes from main transformer tank, is projected inside the
conservator from bottom portion. Head of the conservator pipe inside the conservator is
provided with a cap. This pipe is projected as well as provided with a cap because this design
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prevent oil sludge and sediment to enter into main tank from conservator. Generally silica gel
breather fixing pipe enters into the conservator from top. If it enters from bottom, it should be
projected well above the level of oil inside the conservator. This arrangement ensure that oil
does not enter the silica gel breather even at highest operating level.

Fig 8.1 Conservator Internal View

8.2 Magnetic Oil Gauge

This device is used to indicate the position of transformer insulating oil level in
conservator of transformer. This is a mechanical device. Magnetic oil level indicator of
transformer consists of mainly three parts1.

One float,

2.

Bevel gear arrangement and

3.

An indicating dial.

Lets explain the construction of magnetic oil gauge or MOG from its dial parts. The dial of
this device has scale from empty to full. It has some intermediate divisions such as 1/4, 1/1,
3/4. The prescribed oil level at either 30C or 35C ambient temperature may also be
indicated on the dial. A mercury switch and bevel gear is fixed with pointer. When pointer
35

rotates, the alignment of mercury switch also changes according to the angle of rotation of the
pointer. All oil immersed distribution and electrical power transformers are provided with
expansion vessel which is known as conservator of transformer. This vessel takes care of oil
expansion due to temperature rise. When transformer insulating oil is expanded, the oil level
in the conservator tank goes up.

Fig 8.3 Magnetic Oil Gauge

Again when oil volume is reduced due to fall in oil temperature, the oil level in the
conservator goes down. But it is essential to maintain a minimum oil level in the conservator
tank of transformer even at lowest possible temperature. All large electrical power
transformers are therefore provided with a magnetic oil level indicator or magnetic oil gauge.
In conventional conservator tank, a light weight hollow ball or drum floats on the transformer
insulating oil. The float arm is attached with bevel gear as we already explained during the
discussion on the construction of magnetic oil gauge. Naturally the position of the float goes
up and down depending upon the oil level in the conservator and consequently the alignment
of float arm changes. Consequently, the bevel gear rotates. This movement of bevel gear is
transmitted to the pointer outside the conservator, as this pointer is magnetically coupled with
the bevel gear. The pointer of magnetic oil level indicator is also incorporated with a mercury
switch. So it is need not say, when oil level in the conservator goes up and down, the pointer
moves on the MOG dial to indicate the actual level of transformer insulating oil in
conservator tank. As the alignment of mercury switch changes along with the pointer, this
36

switch closes and actuates an audible alarm when pointer reaches near empty position on the
dial of magnetic oil gauge. This event alerts us for topping up oil in electrical power
transformer.

8.3 Transformer Oil

Transformer oil or insulating oil is an oil that is stable at high temperatures and has
excellent electrical insulating properties. It is used in oil-filled transformers, some types of
high-voltage capacitors, fluorescent lamp ballasts, and some types of high-voltage switches
and circuit breakers. The flash point (min) and pour point (max) are 140 C and 6 C
respectively. The transformer oil is used for the insulation purpose The dielectric strength of
new untreated oil is 12 MV/m (RMS) and after treatment it should be >24 MV/m (RMS).

8.4 Radiator
When an electrical transformer is loaded, the current starts flowing through its windings.
Due to this flowing of electric current, heat is produced in the windings, this heat ultimately
rises the temperature of transformer oil. We know that the rating of any electrical equipment
depends upon its allowable temperature rise limit. Hence, if the temperature rise of the
transformer insulating oil is controlled, the capacity or rating of transformer can be extended
up to significant range. The radiator of transformer accelerates the cooling rate of
transformer. Thus, it plays a vital role in increasing loading capacity of an electrical
transformer.This is basic function of radiator of an electrical power transformer.

Fig 8.4 Transformer Radiator

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The working principle of radiator is very simple. It just increases the surface area for
dissipating heat of the oil. In case of electrical power transformer, due to the transport
limitation, this units are sent separately and assembled at site with transformer main
body. At the time of dispatching, the flings of radiator are blanketed by gasket and
blanketing plates. The radiator valves on the main tank are also blanketed by gasket and
blanketing plates.

Conclusion
I have get through an idea how transformers are being manufactured in S.J. transformers
during the time of summer training. I have seen the core construction, winding construction
and other accessories that are required to manufacture distribution transformers. It has
improved my theoretical concept of transformer. The training also helped me to understand about
manufacturing of transformer more.

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