Contents:-

1. Transformer

2. Working Principle of transformer

3. Parts of Transformer

 Windings) :-
A)Primary winding (H.T.)

b) Secondary winding (L.T.)

 Core (Silicon steel)

 Cooling (ONAN):

a) Heat sink

b) Oil

c) Breather

 Insulation:-

a) Bushes

b) Sleeves

c) Oil

d) Insulation tape

e) Cotton tape

f) Paper tape

g) Press board

h) Bakelite pipe
 I) Drum

 Connectors:

a)Thimble
b) Ferrule

 Cause of major faults in transformer.

 Transformer testing
1. Open circuit test
2. Short circuit test
3. Double voltage double frequency test (L.T. test)
4. Phase test (Series test lamp, H.T. test )
5. Insulation test ( maggar)
6. Turn ratio test
 Transformer

A transformer is a static device which transfers A.C. electrical power by mutual

induction from one circuit to the other at the same frequency but the voltage level is
changed.
 Working Principle of transformer :_

A transformer operates on the principals of “electromagnetic induction”, in the form

of Mutual induction.

 Here:
 VP - is the Primary Voltage
 VS - is the Secondary Voltage
 NP - is the Number of Primary Windings
 NS - is the Number of Secondary Windings
 Φ (phi) - is the Flux Linkage

In a transformer there is no direct electrical connection between the two coil

windings, thereby giving it the name also of an Isolation Transformer. Generally, the
primary winding of a transformer is connected to the input voltage supply and
converts or transforms the electrical powerinto a magnetic field. While the job of the
secondary winding is to convert this alternating magnetic field into electrical power
producing the required output voltage.

A single-phase transformer can operate to either increase or decrease the voltage

applied to the primary winding. When a transformer is used to “increase” the voltage
on its secondary winding with respect to the primary, it is called a Step-up
transformer. When it is used to “decrease” the voltage on the secondary winding
with respect to the primary it is called a Step-down transformer. And third
condition exists when a transformer produces the same voltage on its secondary as is
applied to its primary winding. This type of transformer is called an “Impedance
Transformer” and is mainly used for impedance matching or the isolation of
adjoining electrical circuits.
 Windings

There are basically two windings in distribution transformer.

1. Primary winding: The transformer winding at which input supply is provided is

called primary winding. As we know distribution transformer are stepdown
transformer so we supply a very high voltage to the input winding, thus this
winding is also called High Tension (H.T.) winding.

Size of conductor: Thin wire (Because this winding carries high voltage as well as
smallcurrent,Hence due toeconomicfactor we use thin wire for HT winding.)
Connections: Delta connections (Because in a 3 Phase supply we do not require
neutral wire for transmission so we always connect primary side of transformer in
Delta connections.)

2.Secondary Winding: The transformer winding at which output is taken is called

secondary winding. In distribution transformer the output current is very high and
output voltage is very low as compare to the input supply, Hence this winding is also
called Low Tension (L.T.) winding.
Size of conductor: Thick wire (Because this winding carries a very large amount of
current so a large current requires a thick wire and a small voltage can also easily
pass through thick conductor , Hence due to current carrying capacity a thick
conductor is used forL.T. winding.)
Material Used for windings: Copper is the best material ever for Transformer
windings but due to high cost and theft we use Copper windings only in power
transformer. In Distribution transformer we use Aluminum windings, because
aluminum is very cheaper ascompare to copper. Hence due to economical factor
aluminum windings are used in distribution transformer.

Connections: Star connections (Because our L.T. terminals are output terminals, so
for distribution we must require a Neutral wire, which is only possible when we have
connected our L.T. terminals in Star connections.)

Insulation of Windings: A paper tape is used for providing insulation to both H.T.
and L.T. windings.
2. Core of Transformer

In distribution transformer we use ‘core type ‘transformers.

Material of core: Silicon Steel is the best ever material for transformer core.
Practically we place layer of varnish over the silicon steel limb for providing
insulation between the limbs.

Core of 3 phase transformer: E-I type

 Cooling in 3 phase Distribution Transformer:

Oil Natural Air Natural (ONAN) cooling is the most commonly used way of
transformer cooling. There are two important parts of ONAN cooling

1. Heat sink: A heat sink is basically a heat absorber, it is placed over the body
of transformer in contact with natural air. Heat sink is a hollow or pipe type
structure through which oil flows and the natural air contact helps to cool the
transformer oil.

2. Conservator tank: It is basically oil storage of transformer oil. Here oil

expands, when oil gets hot, so this tank is always filled ¼ % or 1/3 % of the
volume of conservator tank due to expanding of oil.
 3. Breather is placed at the output pipe of conservator tank which do not
allows moisture content to enter the transformer. It consist of a indicating
jelly. The name of this gel is silica gel.

Normal condition color: Blue

Fully absorbed moisture: pink
Damaged: white

4) Transformer oil: Oil play a vital role in transformer,it acts as both

insulator and cooling agent.

Material of transformer oil: Mineral oil

Working of Oil in transformer: while operation of transformer heat is

developed inside transformer windings, so due to such heat transformer oil
starts revolving inside the heat sink and expands in conservator tank and oil
get cooled inside heat sink and conservator tank.

Insulation: This is the most important part of transformer,Most of the faults

occurs in transformer due to insulation.
 Different type of insulators

1. Bushes: It is insulator which is used at both the input and output terminal of
transformer.

Material: Porcelain is the most widely used material for bushes.

NOTE: we always use Bushes for 11KV or above 11KV voltage.

H.T. bushes
 L.T. bushes

2. Sleeves: It is a pipe like structure made of cloth and properly insulated by

plastic which makes it moisture resistant and tough.

Use: It is used to insulate the transformer terminals and joints.

NOTE: while making internal connection of H.T. winding we always place a layer
of paper tape and two layers of sleeves for providing proper insulation.

3.) Paper Insulator: It is basically a big role of paper which is wound over the core
of transformer before placing L.T. winding.
4.) Paper tape: It is a small role of paper which is wound over the terminals with the
help of fevicol for providing insulation.

5.) Mineral oil is placed inside which act as a insulator.

6.) Cotton tape: It is a small role of cotton which is wound over the paper tape for
providing proper insulation.
7. Pressboard or Cardboard: It is one of the most important insulator of
transformer. It is a hard cardboard which provide insulation to core and H.T.
internal connections and act as drum.

8. It is a circular cylinder made of Pressboard having two circular layers which

provide insulation between L.T. and H.T. winding.
 9. Bakelite pipe: It is a pipe made of paper and a varnish layer is provided over
it to make it hard. It is used at internal connections of H.T. winding.

Connectors:

Both Thimble and Ferrule are connected with die. There are different materials for
connectors like copper and aluminum.

1. Thimble: It is used for making end terminals of output connection to H.T. and
L.T. winding.
 2. Ferrule: It is similar to thimble,but it is used for making internal
connections of H.T. and L.T. winding.

Disassembling Of transformer

1. Remove seal nut bolts from transformer main tank.

2. Remove the nuts from the H.T. bushes of transformer.
3. Remove the main cover of transformer.

4. Remove the L.T. connections from transformer main body.

5. Takeout the transformer core and windings from transformer body with
the help of crane.

6. Remove the iron rods placed for transformer support

7. Remove the channels ( angle iron)
8. Remove the core of transformer.
 9. Remove the damaged windings.

10. Remove the cotton tape from transformer core.

Transformer assembling
1. Clean the core of transformer by dry cloth or brush
2. Place cotton tape over the core of transformer for providing support to core.

3. Place1 2 -3 layers of insulation paper over the core for providing insulation to
L.T. winding and removing air gap between core and L.T. winding.
4. Place the L.T. winding over insulation paper.
5. Now place a cardboard drum having two layers over the L.T. winding (
Cardboard drum is used for providing proper insulation between L.T. and H.T.
winding otherwise L.T .and H.T. windings will get short circuited)
6. Now place the H.T. winding over the Cardboard drum.
(Our H.T. winding carries a very large amount of voltage so if we place
L.T. winding over H.T. winding then we have to provide a very high
insulation over H.T. winding to protect L.T. winding but this process is very
costly.
So, we always place H.T. winding over L.T. winding which requires less cost
for insulation between both the windings.)
7. Now check the air gap between H.T. and L.T. winding and remove it by
placing cardboard stripsbetween them.
(If we do not remove this air gap between L.T. and H.T. windings, then our
transformer will produce a large sound called Humming while operation)

8. Now place the core roughly and make temporary connections and check the
turns ratio of transformer
9. After making a proper turn ratio remove the core and make Delta connections
of H.T. winding with ferrule and properly insulate it with sleeves.
10 . Now place the transformer core properly in proper spaceprovided called
steps.

11 . Now we have to place the channels but beforeplacing channels we

provide a proper insulation layer between the core and channel which is
made up of hard card board.
12 . Now we place an earth strip over core and channel of the transformer for
providing proper earthing.
13 . Now properly fix the channel and support rods of transformer.
14 . Now make star connections of L.T. winding, delta connections of H.T.
winding and properly insulate them by insulation paper.

Note:Always follow the standard that the neutral terminal must be at the right
end.
15 Now again insulate the star connections by cotton tape.
16. Now again check the turns ratio by T.T.R meter.
17. Now place the transformer core inside the oven for whole night to remove
moisture content.
18. Now place the transformer windings inside the transformer body and
properly tight the nut bolts of windings withtransformer body so that the
windings will not move from there proper place while transportation.
19. Now place a cardboard between H.T. connections and transformer body
for providing insulation to H.T. side.
20. Now make the L.T. connections through brushes.
21. Place a over main tank of transformer to prevent moisture and oil leakage.
22. Now place the transformer cover over the transformer body and make the
H.T. connections through bushes.
23. Now put mineral oil inside the transformer body and fill whole of the
main tank with mineral oil.

24. Now properly place the transformer cover over the main tank of
transformer and tightly connect the nut, bolts of the transformer cover
with transformer body.
Cause of major fault in transformer.

1. Lack of transformer oil: With the passage of time transformer oil decreases so
due to this lack of oil transformer will not cool properly, which results in
heating of windings and cause damage to transformer.
2. Due to heavy load on a phase of transformer, it may cause in heating of L.T.
winding which results in melting of L.T. winding.
3. Due to loose connections of transformer.

Testing of transformer.

Double voltage and double frequency test:

DVDF (Double voltage and double frequency)test: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 E rms can be deduced by
the equation.
Erms= 4.44ᴓmfN volts
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 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.

Open Circuit or No Load Test On Transformer:

Open circuit test or no load test on a transformer is performed to determine 'no load
loss (core loss)' and 'no load current I0'. The circuit diagram for open circuit test.

Usually high voltage (HV) winding is kept open and the low voltage (LV) winding
is connected to its normal supply. A wattmeter (W), ammeter (A) and voltmeter (V)
are connected to the LV winding. Now, applied voltage is slowly increased from
zero to normal rated value of the LV side with the help of a variac. When the applied
voltage reaches to the rated value of the LV winding, readings from all the three
instruments are taken.
The ammeter reading gives the no load current I0. As I0 itself is very small, the
voltage drops due to this current can be neglected.
The input power is indicated by the wattmeter (W). But, as the other side of
transformer is open circuited, there is no output power. Hence, this input power only
consists of core losses and copper losses. But as described above, short circuit
current is so small that these copper losses can be neglected. Hence, now the input
power is almost equal to the core losses. Thus, the wattmeter reading gives the core
losses of the transformer.

Short Circuit or Impedance Test on Transformer

In this test the LV side of transformer is short circuited and wattmeter (W),
voltmere (V) and ammeter (A) are connected on the HV side of the transformer.
Voltage is applied to the HV side and increased from the zero until the ammeter
reading equals the rated current. All the readings are taken at this rated current.

The ammeter reading gives primary equivalent of full load current (Isc).
The voltage applied for full load current is very small as compared to rated voltage.
Hence, core loss due to small applied voltage can be neglected. Thus, the wattmeter
reading can be taken as copper loss in the transformer.
Therefore, W = Isc2Req....... (where Req is the equivalent resistance of transformer)
Zeq = Vsc/Isc.
Therefore, equivalent reactance of transformer can be calculated from the formula
Zeq2 = Req2 + Xeq2.
These, values are referred to the HV side of the transformer.
Hence, it is seen that the short circuit test gives copper losses of transformer and
approximate equivalent resistance and reactance of the transformer.

Insulation Resistance Test or Megger Test:

Insulation resistance test of transformer is performed in Transformer repair

workshop to check out the insulation of all 3phases of transformer without opening it
(To check short circuit).

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.
Note: It is not necessary to perform insulation resistance test in all three phase
transformer, because both the HV and LV windings are internally connected
together in delta and Star respectively.
Transformer Turn ratio:

The difference in voltage between the primary and the secondary windings is
achieved by changing the number of coil turns in the primary winding ( NP )
compared to the number of coil turns on the secondary winding ( NS ).As the
transformer is basically a linear device, a ratio now exists between the number of
turns of the primary coil divided by the number of turns of the secondary coil. This
ratio, called the ratio of transformation, more commonly known as a transformers
“turns ratio”, ( TR ). This turns ratio value dictates the operation of the transformer
and the corresponding voltage available on the secondary winding.

It is necessary to know the ratio of the number of turns of wire on the primary
winding compared to the secondary winding. The turns ratio, which has no units,
compares the two windings in order and is written with a colon, such as 3:1 (3-to-1).
This means in this example, that if there are 3 volts on the primary winding there
will be 1 volt on the secondary winding, 3 volts-to-1 volt. Then we can see that if the
ratio between the number of turns changes the resulting voltages must also change
by the same ratio, and this is true. In other words for a transformer: “turns ratio =
voltage ratio”.

Phase test:

This test is performed during repair of transformer to check the short circuit and
continuity between LT and HT winding of transformer.
In this test we provide 230volt A.C. supply to H.T. winding of transformer. If the
bulb glow dim without any sparking in the winding then our windings are OK,
otherwise there is a short circuit.