CHAPTER 1

INTRODUCTION

KEL is one among the largest, most vibrant, and productive Public Sector
Undertaking, and is fully owned by the Government of Kerala. A multi-product
engineering company, consistently catering to an envious client base, ranging from
the army and air force of India to world-renowned space research organizations,
highly competent engineering companies to mammoth institutions likes the Indian
Railways. The company with four state-of-the-art manufacturing units spread
across Kerala has a pan India presence with marketing offices in major metros and
select cities. To be a globally recognized enterprise committed to enhancing
stakeholder value by providing world class engineering and power system
solutions.
The company manufactures and markets products like general purpose
brushless alternators, brushless alternators for lating and air conditioning of rail
coaches, medium power and distribution transformers as well as structural steel
fabrication
The product categories for defense application includes high frequency
alternators , frequency convertors , special alternators and power packs for missile
project , the power packs designed and supplied by the company for missile project
like falcon, prithvi, trishul and akash have been pioneering efforts’. The company
has also supplied special alternators to the army (military power cars) and air force
(radar applications)
The companies all India marketing network with regional offices in all metro
cities cater to major institutional clients like the state’s electricity boards , Indian
railways and various defense establishments besides the general market clients

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 CHAPTER 2

GENARAL DETAILS OF A TRANSFORMER

A transformer is an electrical device which, by the principles of

electromagnetic induction, transfers electrical energy from one electric circuit to
another, without changing the frequency. The energy transfer usually takes place
with a change of voltage and current. Transformers either increases or decreases
AC voltage. Transformers are used to meet a wide variety of needs. Some
transformers can be Several stories high, like the type found at a generating station
or small enough to hold in your hand, which might be used with the charging
cradle for a video camera. No matter what the shape or size, a transformers
purpose remains the same: transforming electrical power from one type to another,
There are many different types of transformers in use today. This resource will
take a closer look at Power Transformers, Auto Transformers, Distribution
Transformers, Instrument Transformers, Isolation Transformers, Potential
Transformers and Current Transformers.

How Transformers Work

It is important to remember that transformers do not generate electrical power;
they transfer electrical power from one AC circuit to another using magnetic
coupling. The core of the transformer is used to provide a controlled path for the
magnetic flux generated in the transformer by the current flowing through the
windings, which are also known as coils. There are four primary parts to the basic
transformer. The parts include the Input Connection, the Output Connection, the
Windings or Coils and the Core.

 Input Connections-The input side of a transformer is called the primary

side because the main electrical power to be changed is connected at this
point.

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  Output Connections-The output side or secondary side of the transformer is
where the electrical power is sent to the load. Depending on the Requirement
of the load, the incoming electric power is either increased or decreased.

 Winding-Transformers have two windings, being the primary winding and

the secondary winding. The primary winding is the coil that draws power
from the source. The secondary winding is the coil that delivers the energy
at the transformed or changed voltage to the load. Usually, these two coils
are subdivided into several coils in order to reduce the creation of flux.

 Core-The transformer core is used to provide a controlled path for the

magnetic flux generated in the transformer. The core is generally not a solid
bar of steel, rather a construction of many thin laminated steel sheets or
layers. This construction is used to help eliminate and reduce heating.
transformers generally have one of two types of cores: Core Type and Shell
Type. These two types are distinguished from each other by the manner in
which the primary and secondary coils are place around the steel core.

o Core type-With this type, the windings surround the laminated core.

o Shell type-With this type, the windings are surrounded by the

laminated core.

When an input voltage is applied to the primary winding, alternating current

starts to flow in the primary winding. As the current flows, a changing magnetic
field is set up in the transformer core. As this magnetic field cuts across the
secondary winding, alternating voltage is produced in the secondary winding. The
ratio between the number of actual turns of wire in each coil is the key in
determining the type of transformer and what the output voltage will be. The ratio
between output voltage and input voltage is the same as the ratio of the number of
turns between the two windings, A transformers output voltage is greater than the
input voltage if the secondary winding has more turns of wire than the primary

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winding. The output voltage is stepped up,and considered to be a “step-up
transformer”, If the secondary winding has fewer turns than the primary winding,
the output voltage is lower. This is a “step-down transformer".

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 CHAPTER 3

CONSTRUCTION OF TRANSFORMER

1. OIL COOLED TRANSFORMER

BASIC CONSTRUCTION OF TRANSFORMER

Basically a transformer consists of two inductive windings and a laminated

steel core. The coils are insulated from each other as well as from the steel core. A
transformer may also consist of a container for winding and core assembly (called
as tank), suitable bushings to take or the terminals, oil conservator to provide oil in
the transformer tank for cooling purposes etc. The figure above illustrates the basic
construction of a transformer.

In all types of transformers, core is constructed by assembling (stacking)

laminated sheets of steel, with minimum air-gap between them (to achieve
continuous magnetic path). The steel used is having high silicon content and
sometimes heat treated, to provide high permeability and low hysteresis loss.
Laminated sheets of steel are used to reduce eddy current loss. The sheets are cut
in the shape as El and L. To avoid high reluctance at joints, laminations are stacked
by alternating the sides of joint. That is, if joints of first sheet assembly are at front
face, the joints of following assemble are kept at back face.

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 CORE BUILDING

 The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO)

Silicon Steel
 It is in the form of thin sheets & cut to size as per design.
 Generally three different shapes of core laminations are used in one
assembly.
 Notching is performed to increase the magnetic path.
 The laminations are put through annealing process.
 These laminations are assembled in such a manner that there is no air gap
between the joints of two consecutive sheets.
 The entire assembly is done on a frame commonly known as core channel.
These frames being used as a clamping support of the core assembly.

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COIL WINDING

1. High Voltage Coils: H.V. Coils are the components of finished transformers.
They are made on automatic layer setting winding machines.
 A solid cylindrical former of predetermined length is being used as base
over which is made.
 Generally round insulated wire of either copper or Aluminum (Al) is used
as basic raw material. The coils are made in up of number of layers.
 The starting and finishing leads of each coil are terminated on either side of
the coil.
 These leads are properly sleeved and locked at number of points.

2.Low Voltage Coils:

 L.V. Coils are also one of the components of transformer. The procedure of
making low voltage coil is generally same as described earlier
 The shape of the basic raw-material (Al or Cu) is rectangular.

The Test: The Turn Test is carried out on the H.V. Coils as per the specifications.

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ASSEMBILING

• The components produced in the coil winding and core assembly stage are then
taken into core-coil assembly stage.

• The core assembly is vertically placed with the foot plate touching the ground.
The top yoke of the core is removed. The limbs of the core are tightly wrapped
with cotton tape and then varnished

• Cylinder made out of insulating press board/preshrank paper is wrapped on all the
three limbs.

• Low Voltage Coil is placed on the insulated core limbs.

• Insulating block of specified thickness and number are placed both at the top and
bottom of the L.V Coil.

• Cylinder made out of corrugated paper or plain cylinder with oil ducts are
provided over L.V Coil.

• H.V. Coils are placed over the cylinder.

• Gap between each section of H.V. Coils including top & bottom clearances is
maintained with the help of oil ducts, as per the design/drawings.

• The Top Yoke is refilled. Top core frame including core bolts and tie rods are
fixed in position.

• Primary and secondary windings are connected as per the requirements. Phase
barrier between H.V. phases are placed as per requirement.

• Connections to the tapping switch (if required) are made.

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REBLADING

 The core assembly is vertically placed with the foot plate touching the
ground. The top yoke of the core is removed.
 he limbs of the core are tightly wrapped with cotton tape and then
varnished. Cylinder made out of insulating press board is wrapped on all the
three limbs. Low Voltage Coil is placed on the insulated core limbs.
 nsulating block of specified thickness and number are placed both at the top
and bottom of the L.V Coils Cylinder made out of corrugated paper or plain
cylinder with oil ducts are provided over L.V Coils.
 H.V. Coils are placed over the cylinder. Gap between each section of H.V.
Coils including top & bottom clearances is maintained with the help of oil
ducts, as per the design/drawings. The Top Yoke is refilled. Top core frame
including core bolts and tie rods are fixed in position. Primary and
secondary Windings are connected as per the requirements

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TERMINAL GEAR ASSEMBLY

Terminal gear assembly done as described below:

 Cutting the leads as required.

 Crimping/brazing of the leads with cables.

 Crimping/brazing of the leads with cables.

 Crimping/brazing of cables with terminal lugs.

 Mounting of the tap changer/tap switch.

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TANKING

The core-coil assembly and tank supplied by the fabrication depth. Are taken into
tank-up stage. The procedure is:
The core-coil assembly is taken out of the oven and the "Megger test" is carried
out.
• Only if the megger value is as per the specification, the assembly may be taken
for tank-up.

• The tanks, supplied by fabrication depth. Are brought to tank-up department duly
painted.

• Fittings like drain valves, HV& LV Bushings, conservator, oil level indicator and
explosion vet fitted in the tanks.

• The Core-coil assembly is then placed in to the tank and properly locked up.

• Pure Filtered transformer oil is filled in the tank to immerse the assembly only.

• Connections of primary and secondary to the terminal bushings are made.

Operating handle for ratio switch is tatted, wherever required

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PAINTING

The entire procedure of painting is done under two stages:

1. Cleaning of tanks.

 The cleaning of tank is done normally by chipping / grinding

 The outside surface of the tank is short blasted to achieve a very fine and
smooth finish

2. Painting of tanks

 After cleaning the tanks, a coat of hot oil resistance paint is applied on the
internal surface of the tank,
 The outside surface is painted with a coat of Red Oxide primer and
subsequently with one coat of enamel paint as per customer’s requirement

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 2. THE CAST RESIN TRANSFORMER

Transformers are electric equipment that changes the voltage and the current
of electricity to facilitate its efficient transmission and distribution Transformers
are commonly used at power generation facilities to increase voltage and to
decrease current in order to transport electric energy across transmission lines.
When the electricity reaches the end user, transformers are used to reduce voltage
and to increase current to make the electricity suitable for general use. The process
of transforming voltage results in energy loss that is released in the form of heat
and therefore transformers must contain effective cooling systems. Transformers
are differentiated by their cooling systems (this is one of several ways that the
transformer industry classifies its products) Dry type transformers dissipate heat
directly into the ambient air. Liquid cooled transformers (e.g. oil filled
transformers) dissipate heat into liquid mediums.

The cast resin transformer is a dry type transformer first developed in

Germany in the 1960 as an alternative to oil-Filled transformers. In contrast to an
oil Filled transformer, which immerses coils in oil to absorb and disperse heat, the
coils of a cast resin transformer are coated with epoxy resin, which is able to
withstand temperatures as high as 188 degree Celsius. Heat passes through the
epoxy and dissipates into the surrounding air. The cast resin transformer does not
compete with oil filled transformers in all applications. Most step up transformers

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at power plants that increase the voltage to hundreds of thousands of volts are oil
Filled transformers, because at such high voltages the amount of heat generated is
more efficiently dissipated through a liquid medium. However, many step down
transformers located in the electricity distribution network and at the end user’s
site are dry type transformers. Certain wind and solar farms also use dry type
transformers to step up electricity for transmission. The cast resin transformer has
several advantages over the oil filled transformer, including greater efficiency, less
maintenance, greater fire resistance, and more environmentally friendly (the lack
of cooling liquids eliminates the possibility of oil leaks). While oil-filled
transformers are still widely used in China and throughout the world. we believe
cast resin transformers are increasing in popularity because of these advantages.

PROPERTIES OF RESIN QUARTZ

Cast resin transformers are insulated with an epoxy resin/ Quartz ,powder
mixture this is environmentally friendly material that makes the winding
maintanance-free,moisture resistant, flame retardant and self-Extinguishing this
eliminates the needs for additional flame-retardant chemicals such as aluminum
oxide, which can negatively affect mechanical properties of as well as aging even
when the insulation is exposed clamped between resilient spacers that provide
effective Vibration insulation both from the iron core and mutually between
windings
The copper coils are insulated with quartz powder and then cast with epoxy
resin in an automated vacuum casting machine to provide further insulation the
vacuum casting machine removes all moisture and condensation between the
copper wire and the resin coating Material in order to ensure that none of the
windings crack Wen heat is produced in the transformer as the expansion of
coefficient of copper is similar to the expansion coefficient of epoxy felon and
fiberglass

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ADVANTAGES 0F CAST RESIN TRANSFORMER

Safety

• .Cast resin transformers are fire resistant as opposed to oil-filled transformers.

Which are highly flammable and potentially very dangerous.

• In the case of a short circuit. Cast resin transformers won‘t cause catastrophic
damage. Because cast resin has better structural integrity, it will withstand a short
circuit much better than oil-filled or VPI transformers.

Environmental Friendliness

• Unlike oil-Filled transformers. Cast resin transformers contain no contaminants

that could leak or otherwise escape into the environment.

• Cast resin never requires expensive cleanup.

Efficiency

• Cast resin is very efficient -equal or ≤ 98% and especially more efficient than
VPl.

• Cast resin transformers are air-cooled, so they have considerably Lower losses.

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 CHAPTER 4
TESTS OF TRANSFORMER

INSULATION RESISTANCE TEST

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.
Procedure of Insulation Resistance Test of Transformer

 First disconnect all the line and neutral terminals of the transformer.
 Megger leads to be connected to LV and HV bushing studs to measure
insulation resistance IR value in between the LV and HV windings.
 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.
 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.
 Measurements are to be taken as Three winding transformer: HV to LV, LV
to HV, HV to LV, HV to EARTH

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 Oil temperature should be noted at the time of insulation Resistance test of
transformer. Since the IR value of transformer insulating oil may vary with
temperature. IR values to be recorded at interval of 15 seconds, 1 minute and 10
minutes.

WINDING RESISTANCE TEST

Transformer winding resistance measurement is carried out as a type test,

routine test and also as a Field test. In the factory, it helps in determining the
following:

 Calculation of the ilk losses in transformer.

 Calculation of winding temperature at the end of temperature rise test of
transformer.
 As a benchmark for assessing possible damages in the field. It is done at site
in order to check for abnormalities due to loose connections, broken strands
of conductor, high contact resistance in tap changers, high voltage leads and
bushings.

Procedure of Transformer Winding Resistance Measurement

For star connected Winding, the resistance shall be measured between the line and
neutral terminal. For star connected autotransformers the resistance of the HV Side
is measured between HV terminal and LV terminal, then between LV terminal and
the neutral. For delta connected windings, measurement of winding resistance
shall be done between pairs of line terminals as in delta connection the resistance
of individual winding cannot be measured separately, the resistance per winding
shall be calculated as per the following formula:

Resistance per winding = 1.5 x Measured value The resistance is measured at

ambient temperature and then converted to resistance at 75°C for all practical
purposes of comparison with specified design values, previous results and
diagnostics. Winding Resistance at standard temperature of 75° C

Rts = Rt( 235+75)/(235+t)

Rt=winding resistance at temperature t t = Winding temperatur

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BREAKDOWN VOLTAGE

To assess the Insulating property of dielectric transformer oil a sample of the

transformer oil is taken and is break down voltage is measured

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

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

break down voltage with constant, standard compliant slew rate of e.g.2KV/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 of automatically
by the testing devise. ultra-fast switch off is highly desirable as the carbonization
due to electric arc must be limited to keep the additional pollution as low as
possible

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DOUBLE VOLTAGE AND DOUBLE FREQUENCY 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
sometime: 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 that in the
core of the transformer. This flux links both primary and secondary winding: and
due its alternating nature BMF in induced across both windings and Erms can
deduced by the equation.
Erms= 4.440.ø volts
Where Erms is RMS voltage induced
øm is maximum flux linked
f is the operating frequency
N to the number of turns in the winding.

As per the above equation. When double the rated voltage in 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 M G 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 land capability of the TR. Thus the test is named as
DVD TEST.

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TESTING OF TRANSFORMER

a) Short circuit test

The test is conducted on the high-voltage (HV) side of the transformer

where the low-voltage (LV) side or the secondary is short circuited A
wattmeter is connected to the primary. An ammeter is connected in series
with the primary winding. A voltmeter is optional since the applied voltage
is the same as the voltmeter reading. The LV side of the transformer is short
circuited. Now with the help of varies 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 meter
reading gives the primary equivalent of full load current IL. 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.

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b) Open Circuit Test

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 L V side with the help of a varies of variable ratio auto transformer.
HV side of the transformer is kept open. Now with the help of varies.
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.

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 CHAPTER 5

CONCLUSION

The Industrial Visit to Kerala Electrical & Allied Engineering Co.Ltd helps
team a lot of things which I had never learned from my academics. The culture of
the organization, office etiquettes and the unique management model will give a
deep insight about the industry and definitely it will pave my way to success.
During this visit I got the opportunity to familiar with the different steps of making
transformer. I took this opportunity to thank all the staffs of Kerala Electrical &
Allied Engineering Co.Ltd.

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 REFERENCES

 Operation manual
 www.wikipedia.com
 www.google.com

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