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1 INTRODUCTION ABOUT ATLANTA

1.1 Company Profile And History:-

Incorporated in the year 1983, ―Atlanta Electricals Pvt. Ltd.”,

has consolidated its position in the power generation and transformer
industry as a manufacturer of wide range of special application transformers
that match national as well as international quality standards. Having ISO-
9001-2008 from NABCB, ISO 14001-2004 & OHSAS 18001-2007
certification, the company today is proud of have designed, manufactured
and successfully commissioned more than 4500 Transformers. Our clientele
include various State Electricity Boards and other domestic as well as
foreign Enterprises such as Private Electricity supplying companies, Steel
Plants, Hydel Power Projects, Windmill Plants, Textile units, Oil units, etc.
Committed to highest level of services and excellence, the company
initially emerged as a partnership firm under the Atlanta Electricals. The
capability to develop world emerged as a distribution, and specialty
transformer is credited to the creation of a world class infrastructure at
Vithal Udyognagar near Anand, one of the developing industrialized cities of
India.
The 'all-in-one' facility at Vithal Udyognagar works cover 26000
square meter land and 7000 Square meter built up area with a production
capacity of 7000MVA per annum. Here production, fabrication, storage,
painting, testing, oil handling, sales and admin functions are undertaken
under one roof increasing production efficiency, reducing transport related
emissions and most importantly for reducing costs & direct supervision on
quality aspects.
We at Atlanta Electricals accentuate conscientious Corporate
Citizenship and strongly follow the concept of CSR. Hence, we have tied-up
with Government Women ITI, Anand, in form of a public-private partnership
agreement.
Driven by passion for excellence and future vision Atlanta have
successfully designed, manufactured, type tested and installed 31.5 MVA,
220 kV & 60MVA, 132kV Class Transformers. The factory is equipped for
manufacturing 160MVA, 220kV Class Transformers.
This facility is equipped with world class modern equipment and
managed by a highly skilled and experienced team of production personnel
who consistently ensure that each and every production activity factors in
an adhere to the high quality benchmarks established by the organization.
 In order to serve the customers with lower lead times and higher
capacity & capability Atlanta has newly established 4000 Sq. meter
built up area for manufacturing 160MVA, 220kV Class Transformers
 For expansion of capabilities up to 315MVA, 400kV Class
Transformers an additional land of 18000 Square meters has been
purchased

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 The manufacturing facility is equipped with all the modern

machineries that are required for a manufacturing capacity of 7,000
MVA per annum

ATLANTA has been promoted and is managed by four technocrats,

having an experience of more than four decades in the field of designing and
manufacturing transformers. All the directors are engineers and have a
complete understanding of this line of business. Apart from well-experienced
directors, there is a team of skilled, dedicated and enthusiastic personnel
who are dynamic enough to respond to the various challenges.
As one of India's leading transformer manufacturing companies, and
one that is held in high esteem, a great deal of relevance is attached to living
up to the image as a value based organization. The company is managed by
skilled, dedicated and enthusiastic technocrats with an experience of more
than four decades in the field of designing and manufacturing transformers.
Over the years, the company has successfully carved a nice for itself
in the industry. Providing conducive environment for the professional and
personal growth of employees Atlanta has inculcating a spirit of integrity
both vertically and horizontally.

1.2 WORKING ENVIRONMENT IN COMPANY:-

Atlanta Electricals takes responsible interest in the environment

impact of its business activities. Its products are designed to contribute to
the improvement in power generation and distribution system whilst
reducing environmental impact. Continuous improvements in the system
have enabled the company to increase production and growth steadily with
minimum damage to the surroundings.
The company aims for continuous improvement in the environment,
prevention of pollution in compliance to environmental regulations. The
company trains and motivates all its employees for implementing the
environmental policy and enhances their performance in respective area of
operation.
For sticking and adhering to the above point ATLANTA has adopted
system and has accredited by ISO-14001: 2004

1.3 Safety In Company:-

Atlanta Electricals is an ethically responsible company operating with

transparency. The company is committed to their employees for providing all
kinds of services related to their health and safety from all hazardous/
accidental events that may occur at the plant.

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The employees are given training for safe working practices followed
by the safety rules.
 Health treatment, which falls under company‘s scope.
 Providing safe and modern tools and equipments.
 By adopting human and earth friendly technology for the
manufacturing of products.
Atlanta has adopted OHSAS system and has been accredited by OHSAS-
18001:2007.

1.4 Quality Policy Of The Company:-

 We are committed to manufacture, service & timely supply of Power,

Distribution and special type of transformers conforming to the
specifications as per the client requirements
 Our supplier chain is well assessed as per our QAP which serves as a
solid foundation for us to put up the best quality product in the
market
 Close inspection of incoming materials, controlling in-process
parameters, timely assessment, upgradation of supplier chain,
thorough inspection and testing of the transformer ensure consistent
high quality standards
 We are committed to continuous improvement in performance
through effective implementation of quality management system

1.5 Vision of the Company:-

The expertise of competent personnel and the benefits of a sound

infrastructure directly translate into Quality products. Each of our
transformers undergo various examinations at different stages of production
and are tested for all routine tests conforming to IS-2026 (Equivalent to IEC-
60076). Regular Quality Checks ensure that each ATLANTA transformer
builds enormous goodwill for the company.
Our transformers up to and including 31.5 MVA 220kV class ,
60MVA, 132/66 kV class are successfully type tested at national Accredited
laboratories like E.R.D.A, Baroda and C.P.R.I(Bhopal, Bangalore).
To serve our esteemed customers, in still better way, in terms of Early
Delivery & so also Higher range of Transformers, ―ATLANTA‖ has now
successfully completed EXPANSION PROJECT for 160MVA, 220 kV class
Power Transformers and the production for 220 kV class transformers has
already started.

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1.6 Mission of the Company:-

Company mission is to become largest Power, Distribution and

Special duty transformers manufacturer in India and global market, known
for its quality technology, fully integrated range, innovative directions,
ethical behaviours and business results.
Build long lasting customer relationship will make us preferred
supplier.

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2 INTRODUCTION OF TRANSFORMERS

2.1 WHAT IS TRANSFORMER?

A transformer is a device that transfers electrical energy from

one circuit to another through inductively coupled conductors—the
transformer's coils. A varying current in the first or primary winding creates
a varying magnetic flux in the transformer's core and thus a
varying magnetic field through the secondary winding. This varying magnetic
field induces a varying electromotive force (EMF), or "voltage", in the
secondary winding. This effect is called inductive.
If a load is connected to the secondary, current will flow in the
secondary winding, and electrical energy will be transferred from the primary
circuit through the transformer to the load. In an ideal transformer, the
induced voltage in the secondary winding (Vs) is in proportion to the primary
voltage (Vp) and is given by the ratio of the number of turns in the secondary
(Ns) to the number of turns in the primary (Np) as follows:

By appropriate selection of the ratio of turns, a transformer thus

enables an alternating current (AC) voltage to be "stepped up" by
making Ns greater than Np, or "stepped down" by making Ns less than Np. The
windings are coils wound around a ferromagnetic core, air-core transformers
being a notable exception.
Transformers range in size from a thumbnail-sized coupling
transformer hidden inside a stage microphone to huge units weighing
hundreds of tons used to interconnect portions of power grids. All operate on
the same basic principles, although the range of designs is wide. While new
technologies have eliminated the need for transformers in some electronic
circuits, transformers are still found in nearly all electronic devices designed
for household ("mains") voltage. Transformers are essential for high-
voltage electric power transmission, which makes long-distance
transmission economically practical.

2.2 PRINCIPLE OF TRANSFORMER

The transformer works on the principle of ‗MUTUAL INDUCTION‘.

An alternating flux in the primary coil will create an alternating flux in the
transformer core, which is linked with the other coil which produces a
mutually induced emf according to faraday‘s laws of electromagnetic
induction.

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A current flowing through a coil produces a magnetic field around the

coil. The magnetic field strength H, required to produce a magnetic field of
flux density B, is proportional to the current flowing in the coil. Figure 1
shown below explains the above principle

Figure 1: Relationship between current, magnetic field strength and flux

A transformer is a static piece of apparatus used for transferring

power from one circuit to another at a different voltage, but without change
in frequency. It can raise or lower the voltage with a corresponding decrease
or increase of current.

Vp = -Np A Vs = -Ns A

Figure 2: Transformer schematic

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When a changing voltage is applied to the primary winding, the back

e.m.fs generated by the primary is given by Faraday‘s law,

EMF = Vp = -Np A --- (1)

A Current in the primary winding produces a magnetic field in the

core. The magnetic field is almost totally confined in the iron core and
couples around through the secondary coil. The induced voltage in the
secondary winding is also given by Faraday‘s law

Vs = -Ns A --- (2)

The rate of change of flux is the same as that in primary winding.

Dividing equation (2) by (1) gives

In Figure 2, the primary and secondary coils are shown on separate

legs of the magnetic circuit so that we can easily understand how the
transformer works. Actually, half of the primary and secondary coils are
wound on each of the two legs, with sufficient insulation between the two
coils and the core to properly insulate the windings from one another and the
core. A transformer wound, such as in Figure 2, will operate at a greatly
reduced effectiveness due to the magnetic leakage. Magnetic leakage is
the part of the magnetic flux that passes through either one of the coils, but
not through both. The larger the distance between the primary and
secondary windings, the longer the magnetic circuit and the greater the
leakage. The following figure shows actual construction of a single phase
transformer.

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Figure 3: Transformer construction

The voltage developed by transformer action is given by

E = 4.44×f×N×Bmax×Acore
Where, E = rated coil voltage (volts),
f = operating frequency (hertz),
N = number of turns in the winding,
Bmax = maximum flux density in the core (tesla), and
Acore = cross-sectional area of the core material in Sq.
meters.

In addition to the voltage equation, a power equation expressing the

volt-ampere rating in terms of the other input parameters is also used in
transformer design. Specifically, the form of the equation is

VA = 4.44×f×N×Bmax×Acore×J×Acond
Where, N, Bmax, Acore and f are as defined above, J is the current
density (A/ sq. mm), and Acond is the coil cross-sectional area (mm2) in the
core window; of the conducting material for primary winding. J depends
upon heat dissipation and cooling.

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2.3 TYPES OF TRANSFORMER

A. Oil filled Transformers

 Power Transformers
 Mobile Transformers
 Distribution Transformers
 Furnace Transformers
a. Induction Furnace Duty
b. Arc Furnace Duty
 Motor Starting Transformers
 Neutral Grounding Transformers
 Rectifier Duty Transformers
 Testing Transformer

B. Encapsulated & VPI transformers

 Air Cooled Transformers
 Cast Resin Transformers
 Boosters & Voltage Regulators

C. Reactors
 Air Core Reactors
 Gap Core Reactors

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3 MANUFACTURING PROCESS OF
TRANSFORMER
 Winding Construction
 Core Assembly
 Core & Winding(Coil) Assembly (CCA)
 Tapping &Tap Changer
 Drying Process
 Tank Construction
 Tanking & Final Fitting
 Fittings & Accessories
 Painting
 Oil Filling & Filtration
 Testing

3.1 Winding Construction:-

Conducting material is used in the windings of the transformer.

Usually the windings are in concentrically to minimize the flux leakages.
There are two types of windings. The coils are wound on the limbs and are
insulated from each other in the basic transformer the two windings wound
on the two different limbs. Due to this leakage flux increases which
affects the transformer efficiency or performance so it should be necessary
that the windings should be very close to each other to increase the mutual
inductance and stray capacitance to improve the high frequency response.
Such cylindrical coils are used in core type transformers and sandwich coils
are very commonly used in shell type transformer here each high voltage
winding lies between two low voltage windings such subdivisions
of windings into small portions reduce the flux leakages.
Transformer windings are designed to meet three fundamental
requirements, viz. mechanical, thermal and electrical. They are cylindrical in
shape and are assembled concentrically. Paper insulated conductors of high
conductivity & soft drawn E.C. Grade copper is used which comply with the
latest Indian as well as international Standards.
Windings are made with great care by well experienced skilled
workers in dust free & temperature controlled environment.
Insulation between layers and turns is based upon the electrical and
mechanical strength level. Interlayer cooling ducts (Axial & Radial) are
provided to minimize the temperature gradient between windings and oil,
and hence the hot spot temperature is kept to a minimum. This also ensures
that the rate of insulation deterioration is minimized and high life
expectancy is achieved.
Transpositions are made in multiple conductor windings, to ensure
uniform current distribution, minimize circulating currents, decrease eddy
current loss and improve the lamination factor.

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3.1.1 TYPES OF WINDING:-

1) Helical Winding
2) Layer Winding
3) Disc Winding
4) Interleaved Winding

Helical Winding Layer Winding

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Disc Winding Interleaved Winding

Helical/Layer windings are most suitable for low voltage windings of

large power transformers to mitigate high current design requirement. For
High voltage windings the disc coils with excellent mechanical strength are
used to take the stresses due to voltage level. Special interleaved or shielded
construction offers most uniform voltage distribution despite system
transient. Specialized disc winding and inter-leaved disc windings are used
having very high series of capacitance giving a very good impulse voltage
performance.
Transpositions are made in multiple conductor windings, to ensure
uniform current distribution, minimize circulating currents, decrease eddy
current loss and improve the lamination factor.
Transformer windings are made almost exclusively of copper, or to be
precise, high-conductivity copper. Copper has made possible much of the
electrical industry as we know it today because, in addition to its excellent
mechanical properties, it has the highest conductivity of the commercial
metals. Its value in transformers is particularly significant because of the
benefits which result from the saving of space and the minimising of load
losses.
The load loss of a transformer is that proportion of the losses
generated by the flow of load current and which varies as the square of the
load current.
This falls into three categories:
 Resistive loss within the winding conductors and leads.
 Eddy current loss in the winding conductors.
 Eddy current loss in the tanks and structural steelwork.

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Resistive loss can be lessened by reducing the number of winding turns, by

increasing the cross-sectional area of the turn conductor, or by a
combination of both. Reducing the number of turns requires an increase in
8m, i.e. an increase in the core cross-section, which increases the iron
weight and iron loss. So load loss can be traded against iron loss and vice
versa. Increased frame size requires reduced winding length to compensate
and thus retain the same impedance, although as already explained there
will be a reduction in the number of turns (which was the object of the
exercise) by way of partial compensation. Reduction of the winding axial
length means that the core leg length is reduced, which also offsets the
increase in core weight resulting from the increased frame size to some
extent. There is thus a band of one or two frame sizes for which loss
variation is not too great, so that optimum frame size can be chosen to
satisfy other factors, such as ratio of fixed to load losses or transport height.
The paths of eddy currents in winding conductors are complex. The
effect of leakage flux within the transformer windings results in the presence
of radial and axial flux changes at any given point in space and any moment
in time. These induce voltages which cause currents to flow at right angles
to the changing fluxes. The magnitude of these currents can be reduced by
increasing the resistance of the path through which they flow, and this can
be effected by reducing the total cross-sectional area of the winding
conductor or by subdividing this conductor into a large number of strands
insulated from each other. (In the same way as laminating the core steel
reduces eddy current losses in the core.) The former alternative increases the
overall winding resistance and thereby the resistive losses. Conversely, if the
overall conductor cross-section is increased with the object of reducing
resistive losses, one of the results is to increase the eddy current losses. This
can only be offset by a reduction in strand cross-section and an increase in
the total number of strands. It is costly to wind a large number of
conductors in parallel and so a manufacturer will wish to limit the total
number of strands in parallel. Also, the extra insulation resulting from the
increased number of strands results in a poorer winding space factor.
Compact size is important for any item of electrical plant. In
transformer windings this is particularly so. The size of the windings is the
determining factor in the size of the transformer. As explained above the
windings must have a sufficiently large cross-section to limit the load losses
to an acceptable level, not only because of the cost of these losses to the user
but also because the heat generated must be removed by the provision of
cooling ducts. If the losses are increased more space must be provided for
ducts. This leads to yet larger windings and thus a larger core is needed to
enclose them. Increasing the size of the core increases the no-load loss but,
along with the increase in the size of the windings, also means that a very
much larger tank is required which, in turn, results in an increased oil
quantity and so the whole process escalates. Conversely, any savings in the
size of windings are repaid many times over by reductions in the size of the
transformer and resultant further savings elsewhere. As the material which
most economically meets the above criteria and which is universally
commercially available, high-conductivity copper is the automatic choice for
transformer windings.

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Winding Construction

3.2 Core Assembly:-

Core is built with Cold Rolled Grain Oriented Silicon Steel, low loss
silicon steel lamination . Bonded core design/ technique is used to eliminate
hole punching and to minimize fixed losses and Magnetizing Current. Use of
HiB grade & Laser scribed Laminations and Rigid clamps significantly
reduce vibrations and noise level. Cooling ducts are provided in large
transformers for efficient circulation of oil to keep temperature of core well
within limit without affecting the flux distortion and also in the core suitable
insulation paper are inserted between some laminations for the purpose of
reducing eddy currents and also minimizing magnetic short circuit.
Core of the transformer is either in square or rectangular in size. It is
further divided into two parts. The vertical position of the core is limbs and
horizontal position of the core is yoke of the core. Core is made up of
laminations to reduce the eddy current losses get minimized. This
lamination is insulated by using insulations line varnish or thick paper.
Paper insulation is used for low voltage transformer and varnish is used for
high voltage transformer.
The step lap or Mitred joints at the core corners ensure a stream line
magnetic flux path. The core limb are held with resin bonded glass bands to
eliminate limb bolts. Yokes are clamped by solid mild steel plates with yoke
stud ensuring high rigidity for withstanding mechanical socks during
transportation & Short Circuits. The leg core in a which hard wooden bars
are inserted, are tighten with synthetic resin impregnated fibre glass tape.

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The transformer core is closed magnetic circuit built up of thin

laminations of electrical sheet steel. It is intended to concentrate the main
magnetic flux linking with the winding and consists of limbs which carry
the windings and yokes which close the magnetic circuit. The core
laminations are insulated from one another by a film of heat-resistant
coating or varnish, or by a combination of both. There may be forms of
magnetic circuit: the shell type and the core type.
A magnetic circuit of the shell types is branched: there are two yokes
per limb, which encircle the limbs on both sides. As the magnetic flux leaves
a limbs, it branches off into two parts, therefore, in shell-type transformers,
the cross-sectional area of the limbs is twice that of the yokes. The limbs
and yokes are rectangular in section, which necessitates the use of
rectangular disk windings. Because of the insufficient strength of such
windings in the event of short circuits, complications in assembly and also
somewhat greater mass of the shell-type magnetic circuits as compared with
the core types circuits using cylindrical windings, the shell type in the Soviet
Union is employed only for single-phase transformers in household
appliances and for some special-purpose transformers.
The core-type magnetic circuits of butt-joint or interleaved construction
are used in power transformers. In such circuits, two or three vertical
circuits are bridged over by two horizontal yokes the top and the bottom one
so that a closed magnetic circuit is formed.
The core limbs and yokes are built up of separate laminations of
electrical sheet steel 0.35 or 0.5 mm think.
The core is built horizontally by stacking laminations, usually two or three
per lay, on a jig or stillage. The lay-down sequence must take account of the
need to alternate the lengths of plates to provide the necessary overlaps at
the mitred corners as shown in shows a large core being built in the
manufacturer‘s works. The clamping frames for top and bottom yokes will be
incorporated into the stillage but this must also provide support and rigidity
for the limbs until the core has been lifted into the vertical position for the
fitting of the windings. Without clamping bolts the limbs have little rigidity
until the windings have been fitted so the stillage must incorporate means of
providing this. The windings when assembled onto the limbs will not only
provide this rigidity, in some designs the hard synthetic resin-bonded paper
(s.r.b.p.) tube onto which the inner winding is wound provides the clamping
for the leg laminations. With this form of construction the leg is clamped
with temporary steel bands which are stripped away progressively as the
winding is lowered onto the leg at the assembly stage. Fitting of the windings
requires that the top yoke be removed and the question can be asked as to
why it is necessary to build it in place initially. The answer is that some
manufacturers have tried the process of core building without the top yokes
and have found that the disadvantages outweigh the saving in time and cost
of assembly. If the finished core is to have the lowest possible loss then the
joints between limbs and yokes must be fitted within very close tolerances.
Building the core to the accuracy necessary to achieve this without the top
yoke in place is very difficult. Once the windings have been fitted the top
yoke can be replaced, suitably interlaced into the projecting ends of the leg
laminations, followed by the top core frames. Once these have been fitted,
together with any tie bars linking top and bottom yokes, axial clamping can
be applied to the windings to compress them to their correct length.

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The reason we laminate the iron cores in transformers is because we

want to limit what are called eddy currents. Transformers are basically two
coils of wire wrapped around a core of iron. They work by induction.
Induction occurs when current flows in one conductor (or one set of
windings in the transformer) and the magnetic field that forms around that
conductor (that set of windings) sweeps the other conductor (the other set of
windings) and induces a voltage. In order to increase the effectiveness of the
transformer, we need to improve the way the magnetic fields are coupled
from one set of windings to the other set. Iron conducts magnetic lines of
force well, so we use that to help conduct the magnetic lines of force from
coil A to coil B. Problem is, iron is also a conductor, and it's being swept by
the magnetic field as well. If we didn't use laminations, the iron core would
provide a place for the magnetic lines to produce (induce) current, and that
current flowing in the core would heat the core up really fast and waste
energy.

Before concluding the description of core construction, mention

should be made of the subject of core earthing. Any conducting metal parts
of a transformer, unless solidly bonded to earth, will acquire a potential in
operation which depends on their location relative to the electric field within
which they lie. In theory, the designer could insulate them from earthed
metal but, in practice, it is easier and more convenient to bond them to
earth. However, in adopting this alternative, there are two important
requirements:
1. The bonding must ensure good electrical contact and remain secure
throughout the transformer life.
2. No conducting loops must be formed, otherwise circulating currents
will result, creating increased losses and/or localised overheating.

Metalwork which becomes inadequately bonded, possibly due to

shrinkage or vibration, creates arcing which will cause breakdown of
insulation and oil and will produce gases which may lead to Buchholz relay
operation, where fitted, or cause confusion of routine gas-in-oil monitoring
results by masking other more serious internal faults, and can thus be very
troublesome in service.
The core and its framework represent the largest bulk of metalwork
requiring to be bonded to earth. On large, important transformers,
connections to core and frames can be individually brought outside the tank
via 3.3 kV bushings and then connected to earth externally. This enables the
earth connection to be readily accessed at the time of initial installation on
site and during subsequent maintenance without lowering the oil level for
removal of inspection covers so that core insulation resistance checks can be
carried out.
In order to comply with the above requirement to avoid circulating
currents, the core and frames will need to be effectively insulated from the
tank and from each other, nevertheless it is necessary for the core to be very
positively located within the tank particularly so as to avoid movement and
possible damage during transport. It is usual to incorporate location
brackets within the base of the tank in order to meet this requirement.
Because of the large weight of the core and windings these locating devices
and the insulation between them and the core and frames will need to be
physically very substantial, although the relevant test voltage may be
modest.

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Core Assembly

3.3 Core & Winding(Coil) Assembly (CCA):-

L.V. Windings are normally placed near core over insulating cylinder
and oil ducts. HV Windings are assembled co-axially placed with respect to
LV. Spacers between coils are 'T' shaped for added firmness. Coils are
assembled with best insulating materials and are adequately clamped. SPA
methodology is now a day widely adopted to have it's special beneficial
characteristics. The winding is rigidly supported by a common spacer ring of
densified wood at the top and bottom for precise alignment. Well profiled
angled rings are placed between LV & HV windings to reduce voltage stress
level. The ends & tapping leads of all windings are connected by special extra
flexible, insulated copper cables which are rigidly braced in position.

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Core & Winding(Coil) Assembly

3.4 Tapping &Tap Changer:-

Generally Taps are provided on HV Windings for HV Variation or LV

Variation as specified by customer. These are brought up to a gang operated
switch, suitable for external manual operation and can be locked in any
desired position to avoid unauthorized operation.
All the moving contacts are spring loaded to ensure proper pressure
and good contacts.
To achieve precise voltage regulation on load tap changer is used
instead of OCTC. Usually Higher capacity transformers i.e above 5000 KVA
ratings, can be supplied with On Load Tap Changer along with necessary
controls to make it suitable for manual, local electrical or remote Electrical
operation.

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Tap Changer

3.5 Drying Process:-

The core- coil assembly is placed in Vacuum Auto Enclave to eliminate

moisture content which is targeted less than 0.5 % moisture. Drying process
is to be carried out @ 90°C & respective vacuum cycle at rated interval to
improve Insulation resistance and remove ingress of moisture in insulation
material.
Drying of grain involves exposing grain to air with low relative humidity
(RH) which will lead to evaporation of the moisture in the grain and then the
moisture‘s removal away from the grain. Since drying practices can have a
big impact on grain or seed quality, it is important to understand some
fundamentals of grain drying.

3.5.1 Moisture removal

In paddy grain, moisture is present at two places: at the surface of the

grain, ‗surface moisture‘, and inside the kernel, ‗internal moisture‘. Surface
moisture will readily evaporate when grain is exposed to hot air. Internal
moisture evaporates much slower because it first has to move from the
kernel to the outside surface. As a result, surface moisture and internal
moisture evaporate at a different rate. This difference results in a different
‗drying rates‘ for different period of drying. The drying rate is defined as the
rate at which grain moisture content declines during the drying process. It

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is normally expressed in percent moisture removed per hour [%/hr]. Typical

drying rates of rice dryers are in the 0.5%/hr to 1%/hr range.
A drying curve, as illustrated in the figure below, shows how the
grain moisture content (MC) and grain temperature change over time. As
can be seen in the chart, the drying rate is not constant but changes over
time. The temperature of the grain equally changes over time.

Theoretical drying curves with different drying periods.

3.5.1.1 Drying periods and implications optimal drying

There are three different drying periods which will occur consecutively
in time:

 I. Preheating period (drying rate is almost 0):

When wet grain is exposed to hot air, initially only a very slight
change in MC is observed. This happens because all the heat
provided in the drying air is used to heat up the grain to the drying
temperature.
 II. Constant-rate period (drying rate is constant in time):
Once the grain is at the drying temperature, water starts to evaporate
from the surface of the grain. During this period, all the heat from
the drying air is used to evaporate surface moisture and the amount
of moisture removed from the grain is constant in time. It is therefore
called the constant-rate period. During this period, grain temperature
is constant as well.
 III. Falling-rate period (drying rate declines over time):
As time passes, it takes more time for internal moisture to appear at
the surface, and evaporation of water is no longer constant in time.
As a result, drying rate will decline, and some of the heat from the
drying air will heat up the grain. For paddy grain, the falling-rate
period typically occurs at around 18% grain moisture content.

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By using the 18% MC and the drying curve characteristics as a

guideline, a few recommendations can be made in regard to grain drying
procedures. These guidelines can be used regardless whether grain is dried
in the sun or by using artificial grain dryers.

3.5.2 Drying rate and temperature

Above 18% MC the grain drying rate can be increased (that is, drying
will occur faster) by providing a higher temperature or more drying air
without major changes in grain temperature. Below 18%MC increase in
drying air temperature will not increase the drying rate but will increase
grain temperatures and potentially damage the grain. Therefore, higher
drying air temperatures can be used to dry grain quickly down to 18% MC
(to remove "surface moisture") but lower temperatures should be used to
remove internal moisture from the grain.

For seed purposes, drying air temperatures should never exceed 43ºC,
regardless of the MC, to avoid overheating of the grain which kills the germ.
Exposing paddy to 60ºC for one hour can reduce the seed germination rate
from 95% to 30%. Two hours at 60ºC will reduce the germination rate to
5%.

3.5.3 Uniform drying

During the drying process there is always variability in MC of

individual grains. Especially in fixed-bed dryers the grains at the air inlet dry
faster than at the air outlet resulting in a moisture gradient in the grain bulk
at the end of the drying process. For production of good quality grain or
seed, this variability should be kept as low as possible. Frequent stirring in
sun drying, grain turning in fixed bed dryers or circulation in re-circulating
batch dryers will improve uniformity of drying, minimize the re-wetting of
dried grains and thus maintain grain quality.

3.5.4 Tempering

When the drying of grain is temporarily stopped the moisture within

the grain equalizes due to diffusion. When drying is restarted, the drying
rate becomes higher compared to continuous drying. The process of stopping
intermittently is called tempering. In addition during tempering the moisture
differences between grains equalize. Tempering therefore also ensures that
moisture gradients in the grain bulk that develop during drying in certain
dryer types are minimized.

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To maintain grain quality, including a tempering period is

recommended to allow for redistribution of internal moisture in the grain. In
modern re-circulating grain dryers, grain is not dried continuously but goes
through a cycle of drying followed by tempering. This improves drying rates,
grain quality and reduces energy costs.

3.6 Tank Construction:-

Small capacity tanks are fabricated from sheet steel while larger ones
are assembled with cast aluminium. For cooling purpose the tank is welded
with cooling tubes. These are some types of transformer tanks.
Protection of active part in 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 & external
faults 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 Indian /
International standards. A robust skid under base is provided, and guide
bars are located inside the tank to securely fix the core and windings
assembly in position, and to prevent any movement during transportation.

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3.7 Tanking & Final Fitting:-

Dried out Core & Coil Assembly is tightened before application of hot oil
shrinkaging for 24 hours. The oil shrinkaging process avoids looseness of
active parts during it's service at site. At last uniform pressing is done on
Core & Coil Assembly. High mechanical rigidity is achieved by hydraulic
pressing at circulated force and tightening all pressure screws. Pressed Core
& Coil Assembly is put in to the tank with proper locating & locking
arrangements which is of prime importance to achieve high resistivity
against transient damages, vibrations during service and Forces develop
during fault occurrence.
After completion of Core & Coil Assembly insertion in tank, hot, degassed
oil is then allowed into the transformer tank under vacuum. This oil is then
circulated through the transformer and the oil degassing plant until all gas
trapped in the core, windings, and the insulation is removed. This ensures a
high degree of stability in the insulation structure and early attainment of its
mature condition, which would not otherwise be achieved until the
transformer had been in service for some time.
The transformer is made ready for testing after assembly of bushings,
conservators, radiators & all other protective devices .All the joints are
gasketed to avoid leakage with the help of rubberized cork sheets/Nitrite
Rubberized ORing, which can withstand high oil temperature and do not
deteriorate nor contaminate oil in its contact.

Final Fitting

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3.8 Fitting & Accessories:-

3.8.1 Rating & Terminal Marking Plate

The transformer is supplied with rating and terminal marking plate

made out of non-corrosive metal. The plate contains information concerning
the rating, voltage ratio, weights, oil quantity, vector group, etc. The plate
also includes unit Sr. no. and year of manufacturing.

Rating & Terminal Marking Plate

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3.8.2 Tap Changing Arrangement

3.8.2.1 Off-circuit Switch

The transformer is normally fitted with an off-circuit tap changing

switch to obtain required voltage ratio. It can be hand-operated by a switch
handle mounted either or tank cover or on the tank side. The locking device
is fitted to the handle to lock in any tap position. The switch mechanism is
such that it can be locked only when it is located in its proper position and
not in any intermediate position.

The transformer must be isolated from all time the live lines, before
operating the switch.
Operating the switch when transformer is energized, will damage the
switch contacts due to severe arcing between the contacts and many damage
transformer winding.
When switch handle is provided on the side wall, it is necessary that
switch handle assembly is dismantled before undertaking.

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3.8.2.2 Off circuit ratio changing links

Some times links are provided inside the transformer tank to obtain
required voltage ratio. Links are required to be loosened and fixed in new
required position as given in R & D plate. Links are accessible from the
inspection cover. In case of conservator units, oil level has to be lowered
below the inspection cover before unbolting inspection cover.

3.8.2.3 On load tap changer

The on load tap changer is an optional fitting. The on load tap

changers are provided with local manual control, local electrical control and
remote electrical control. The automatic voltage regulation can also be
provided as an optional fittings.
The tappings are located on high voltage winding.

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For further details, please refer to the attached manual of OLTC and
schematics.

3.8.3 Earthing terminals

The core laminations assembly is connected to core clamping frame

which is in turn connected to the tank. Two earthing terminals are provided
on the transformer tank. The earthing terminals should be connected to the
earthing.

3.8.4 Lifting Lugs

Two or four lifting lugs of adequate capacity are provided on a tank

sides/top cover to lift fully assembled transformer filled with oil.
All lugs are designed for simultaneous use and must be used
according. Two or four lifting lugs are provided for undertaking the core and
windings of larger capacity transformer.
All heavy fittings are also provided with individuals lifting lugs.

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3.8.5 Valves

Every transformer is provided with drain cum filter valve at bottom of

tank, and filter valve at top of the tank. Valves are fitted with plugs/blanking
plates to stop oil coming out.
Mainly two types of valves are provided.
1. Wheel valves.
2. Butterfly valves.

The wheel valves are used either with female screw threads or with
flanges. These are of gun metal/cast iron type.
Generally, one isolating valve also known as shut off valves is
provided for transformer up to 2000KVA between conservator and buchholz
relay.
The butterfly type cast steel valves with the machined flanges are
used at points of connection between tank and detachable radiators.

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3.8.6 Bushings
3.8.6.1 Oil Communicating Type

Transformers windings are connected to the external circuit through

terminal bushings. The bushings are installed on the cover or on side walls
of the transformer tank. The lower end of the bushing protrudes in to the
tank and at both their ends are provided with suitable fasteners to connect
the line leads in side the transformer and external conductors out side it.
The shape and size of the bushings depends on the voltage class, type
of current. Electrical performance of these bushings conforms to I.S 2099
and I.S 7421. dimensional details and associated parts generally conform to
I.S 3 up to 36 KV class. Bushings of 1000 volts are of two piece construction
with out arcing horns, whereas all other bushings is possible without
disturbing the active part. For bushings of two piece construction, tank
cover is required to be removed for necessary access to the inner (lower) end
of the bushings. These bushings are not detached at the time of
transportation.

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3.8.6.2 Condenser Bushings

Generally, condenser bushings are used for 72.5KV and above. These
bushings contain their own oil and are sealed to retain the same. Whenever
these bushings are mounted on bushings pockets or raised truncated
portions, air vent pips are provided for carrying away air or gases from these
pockets to Buchholz relay during service typical assembly.
These bushings are detached from the transformers and dispatched
separately. They are packed as per manufacturer‘s instructions. The draw
through type lead is coiled and kept temporarily below the bushing blanking
plate. The equipment required for mounting the bushings are
(1) Rope slings.
(2) Flexible steel wire approx 2mm in diameter, of suitable length.

3.8.7 Cable Boxes

Cable boxes are designed for receiving & protecting cables ends.
Insulating paper is most hygroscopic & all paper insulated cable ends must
be protected by suitable insulating compound. These cable boxes are
provided with brass wiping glands & designed with clearances insides the
box suitables for compound filling. The cable box in such case must be filled
with compound as marked as indicated in the drawling.

Cable boxes of PVC are XLPE cables are designed with air clearances
and hence these boxes are not required to be filled with compound.

Cable boxes of 3.6 KV & above are provided with detachable gland
plates. Earthing terminals are also provided on these cable boxes for
earthing the amounting of individual cable when cable boxes are provided
with disconnecting chambers they permit removal of transformers for
servicing without disturbing cable terminations.

3.8.8 Bus-duct\trunkings

Some users prefer connections to load by means of bus-duct. Bus-

duct is supplied by some other agency However, we provide suitable flanges/
trunkings around transformer bushings for receiving the bus-duct.
The level of the bus-duct flanges from ground/rail level is indicated in
the general Arrangement drawings of the transformer. the complete details of
bus-duct flange is furnished by us giving dimensional details for the
matching flanges, bolt spacing, bushing terminal details, etc

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3.8.9 Marshalling Box

The transformer is provided with curtain fittings directly mounted on

the transformer at various location these fittings are having electrical
contacts or terminals which are required to be connected ton the
protection schemes to give alarm/annunciation under abnormal condition
and if further required to disconnect the transformer from mains. in order to
facilitate connection of all such device to the protective scheme, the cable
form all such contacts are wired up to a weather-proof terminal box. This
box called marshalling box, is also used for housing oil Temperature
indicator (OTI) and winding temperature indicator (WTI).

The marshalling box is made of sheet metal and is provided with a

glass window for observing OTI & WTI.
It has a hinged door with locking facility to prevent un-authorised
access. The capillaries from OTI & WTI come out from to the bottom of the
marshalling through suitably recessed gland plate thus preventing ingress of
dust.

3.8.10 Magnetic Oil level Gauge (MOG)

This is a dial type oil level indicting device provided on large

transformers with conservator at relatively high levels from the ground. In
large transformers conventional glass oil level indicators are difficult to
observe due to their heights and color change/dust accumulation on the
glass. Further, the low oil contacts provided on the magnetic oil level
indicator can be used for automatic alarm when the oil level in the

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conservator falls to a low level. This Protection feature and clear visibility
justify the cost of MOG on a bigger transformer.

It consists of two compartments

(a) The oil side compartment which is fixed on the opening in the
conservator.
(b) The pointer side compartment.

These Compartments are sealed against leakage of oil by a metallic

diaphragm. On the oil side compartment, there is a bevel gear wheel and it is
positioned near the diaphragm. Movement of the float due to rise and fall of
oil level in the conservator results into circular motion of the driving magnet.
A follower magnet is positioned in the pointer side compartment near the
diaphragm. This magnet has its poles face to face to the poles of driving
magnet from the oil side compartment coupling them magnetically. The
movement of float is, therefore, transferred through the diaphragm,
eliminating direct oil light mechanical coupling.
At the other end of the axis of the driven magnet an indication pointer
is fitted. The dial is calibrated to show the oil level in the conservator. The
dial and the pointer area housed behind the front glass. The dial has three
positions marked. The follower magnet has also a cam fitted on it which
operates a mercury switch. When this magnet is at a position corresponding
to low oil level the mercury switch closes the Normally open (NO) contacts.
These contacts are normally wired to give audible alarm. The contacts are
brought to a terminal box at the lower end of the dial, for external
connections.

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Magnetic Oil level Gauge

3.8.11 Oil Temperature indicator (O.T.I.)

 Oil Temperature indicator (O.T.I.) is generally provided on all

transformers except for very small ratings. The direct reading
pointer arrangement in this Instrument greatly facilitates
observation of working temp. of oil. It also helps, if need be, in
deciding the permissible overloads in accordance with I.S. 6600-
1972. Guide for loading of oil immersed transformers.
 A Typical - Oil temperature indicator consists of a
 Bourdon tube with a pointer arrangement mounted in a case
comprising of a reading dial and a glass cover. There is a
temperature sensing bulb which communicated to the Bourdon
tube through the armoured capillary.
 The oil temperature indicator is provided with two pointers and
associated contacts for protection of transformers. Both the
pointers are independently adjustable and can be set to desired
temperature. Setting of these pointers at required temperatures
can be done form outside through the knob by using special keys.
 The OTI is generally housed and wire upto terminal strip in the
marshalling box having a glass window on the door for

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observation. The length of capillary does not influence the

accuracy of measurement and extra length of capillary tubing
must not be cut, as it would break communication between bulb
and Bourdon tube.

If the oil temperature increases beyond set limit due to overload or

inadvertent closure of radiator valves or insufficient air draft, the indicating
pointer touches the present alarm pointer actuates the alarm contacts. The
alarm contacts, when duly wired give an alarm. If the alarm is not attended
and there is a further increase of temperature, the trip contacts which are
wired to the trip circuit will operate and isolate the transformer from mains.

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3.8.12 Winding Temperature Indicator

Generally for transformers of high power rating a Winding

Temperature Indicator is also required and provided.
A typical - Winding Temperature Indicating (W.T.I.) arrangement
provided in a transformer comprises of the following:
(a) W.T.I. Pot
(b) Image Coil
(c) W.T.I. C.T.
(d) W.T.I.
The W.T.I. Pot is mounted at the top of the transformer tank. Hence
the oil in the W.T.I. pot is at a temperature of TOP OIL. The image coil is a
heater coil and develops additional heat raising the temperature of the oil
inside the heater coil. There is a W.T.I. C.T. mounted on one of the line leads
with its secondary feeding the image coil. As the load on the transformer
varies, the line current varies, the W.T.I. C.T. secondary current passing
through the Image Coil varies, the heat developed by Image coil varies and
hence the temperature of the oil inside the Image Coil varies. The bulb of the
W.T.I. is immersed in the oil inside the Image Coil and as seen above the
temperature of this oil is dependent on Top Oil Temperature and the Load on
the transformer.
The W.T.I. Image coil is designed and calibrated to indicate the
Winding Hot Spot Temperature (HST) because this is the temperature which
decides the life of the transformer. Thus the winding Temperature Indicator
(W.T.I.) reads temperature.

Ambient Air Top Oil

Temperature Temp. Rise 1.1 x GRADIENT
Winding Temperature Indicator is also housed in the marshalling box.
W.T.I. also has an alarm and trip contacts which are wired up to terminal
strip. For fan cooled transformers, the auxiliary contacts of W.T.I. are use for
switching ON and OFF the fans.

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Winding Temperature Indicator

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3.9 Painting:-

Metal which has been pre-treated by means of shot blasting to remove

rust and welding scale is thoroughly cleaned, and then a coat of epoxy zinc
chromate primer paint is immediately applied to all external surfaces. This
anticorrosive primer has rust inhibitive properties and excellent chemical
resistance. Two coats of Epoxy or PU paint , which is highly resistant to
chemicals and oil, are then applied. Inside surface of the tank is applied with
HOR paint.

3.10 Oil Filling & Filtration:-

All the Transformers are supplied with first filling of oil conforming to IS
335. Before filling, oil is heated, filtered and vacuum treated in filter
machine to remove any foreign particles, moisture and air.

Oil Filling

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3.11 Testing:-

Before dispatch, each and every transformer is subjected to all routine

tests as specified by IS/IEC/BS/ANSI standards.

3.11.1 TYPES OF TESTING

1. Partial discharge test

2. Noise level measurement
3. Temperature rise test
4. Sweep Frequency Response Analyzer (SFRA) Test

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3.11.1.1 Partial discharge test

Partial Discharges (PD) in the high voltage insulation are local

breakdowns of the insulation which does not result in a complete failure of
insulation. Hence, the discharges are called partial. The change in the PD
value is measured in unit apparent charge pC.

Current transformers and Potential transformer are very important

equipments of any power system for metering and protection. Failure of
these equipments will cause
 Short circuit fault in the system,
 Damage to other surrounding equipment / switchgear and
 Cause Non-availability of the system.

3.11.1.1.1 Reasons for PD in Instrument Transformers

The instrument transformers when manufactured in factory, due to

its manufacturing process workmanship, some voids are present. These
voids over a period of time start increasing in size due to overvoltages in
system or ageing. When a voltage is applied to the object the gaseous
particles start getting ionizing. At a particular stage the void size increases
causing the apparent charge (pC) value to increase and finally cause failure
of the instrument transformer. The failure or increase in PD value can also
be due to moisture or contamination on the external surface of the
equipment which may cause tracking with respect to earth.

3.11.1.1.2 Test Description and Set-up

For this test rated phase to neutral voltage is applied across the
object. A coupling capacitor (having low inductance) is connected across the
test object which converts the input currents to low output voltage. The
output of this coupling capacitor is fed to the PD measuring instrument
which gives the PD value in Pico Coulomb and also indicates the discharges
on the sinusoidal waveform. The most important requirement for this test is
a PD free power source transformer. The circuit for PD testing is shown in
figure below

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3.11.1.1.3 Limiting values and Testing schedule

As per Indian Standard (IS) 11322 – the limiting value of PD in Cast

resin instrument transformer is < 50 pC
Manufacturers limit this value to less than 20 pC before dispatch
from their factory.
PD testing of instrument transformers should be carried out
 Just before commissioning to have the base foot print values at
site.
 Once in every 2 years to trend the ageing or increase in the pC
value and
 Depending upon the pC value measured over a period of
six or twelve months.

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3.11.1.2 Noise level measurement

The test procedure is in accordance with IEC Standard 60076-10.

At first, the background noise level shall be measured. Then, the

transformer shall be powered at rated voltage and frequency under no-load
conditions (with the tap-changer selected on the principal tapping), in order
to carry out transformer noise level measurements.

They shall be performed in several points located around the

transformer, placed at a distance of 0,3 m from the machine unless, due to
safety reasons or following agreement between supplier and purchaser, the
distance is increased to 1m. Measuring positions shall be spaced at a
distance of at most 1 metre one from another; anyway, a minimum of 6
positions is required. The measurements shall be carried out at half the
equipment height, if this does not exceed 2,5m; otherwise, they shall be
performed at 1/3 and 2/3 of the component height.

After performing transformer sound level measurement, the machine

is de-energised and background noise level is measured again; At the end,
the final transformer sound level shall result by applying a correction by
taking into account the lower background noise level. In case there is a high
difference between the transformer and background noise level (>8 dB) no
correction shall be applied.

CONNECTIONN SCHEME

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3.11.1.3 Temperature rise test

The test is for verifying whether the temperature rise limits of the
windings , as agreed at the time of the enquiry, are respected. The test can
be carried out by means of two different methods:
 Simulated loading method (in accordance with. IEC 60726 p.21.1.3)
 The method used is defined at the time of the enquiry.

The average temperature rise shall be determined by means of the

variation of winding resistance. The core temperature rise shall be
determined by use of a thermometer. All the carries at rated conditions shall
be performed in accordance with IEC 60726.

3.11.1.3.1 Simulated loading method

Temperature rise test is made by utilising the rises obtained on two

tests, one with no-load loss only, and one with load-loss only.
The no-load test, at the rated voltage and rated frequency, is
continued until steady state conditions are obtained; individual winding
temperature rises are then calculated by measurement of hot windings
resistance, that shall be carried out as shortly as possible after is
connection. The short-circuit run with rated current flowing in one winding
and the other winding short-circuited, is started immediately following the
no-load run, and continued until steady state conditions are obtained;
individual windings temperature rises are then calculated as above
mentioned. The total winding temperature rise of each winding, with rated
current in the winding and normal exitation of the core, shall be calculated
in accordance with IEC Standards 60726.

CONNECTION SCHEME

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3.11.1.4 Sweep Frequency Response Analyzer (SFRA) Test

The SFRA test is non-intrusive (non-destructive) test. SFRA is an

OFF line testing and it can be carried out for any voltage rating of Power
Transformer, Generator Transformer and Distribution Transformer. The
measurement of SFRA can be a part of regular transformer maintenance.
The SFR Analyzer identifies the following abnormalities in the transformer
before they lead to failure,
a. Core movement
b. Winding deformation and displacement
c. Faulty Core ground
d. Partial winding collapse
e. Hoop buckling
f. Broken or loosened clamping structures
g. Shorted turns and open winding

The Technique of SFRA is a major advance in transformer condition

monitoring analysis. This is a proven technique for making accurate and
repeatable measurements.
The test can be carried out,
a) First to obtain initial signature (record) of the transformer
Sweep frequency response for future reference / comparison.
b) Periodical measurement as a maintenance check, once in two
years.
c) Immediately after a major external Short Circuit, specially for
faults electrically closer to transformer.
d) Transportation or re-location of transformer.
e) Earthquakes.
f) Pre-commissioning check.

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4 INSTALLATION & COMMISSIONING

This section illustrated procedure for installation & Commissioning of
our transformers.
A format of ―Commissioning Report‖ is included at the end of this
section. Results of various pre commissioning tests as well as well as
confirmation of check point are to be recorded in this report. This Report
then would saver as a handy record for future reference.

4.1 Installation

4.1.1 Location

The transformer should be kept in a well ventilated place, free from

excessive dust, corrosive fumes etc. Adequate ventilation is necessary for
tank radiators so that they can dissipate heat. There should be clear space
of about 1.25 m on all sides of the transformers if it is enclosed in a room.

4.1.2 Foundation

Foundation should be firm, horizontal and dry. Where rollers are

fitted, suitable rails should be provided.

4.1.3 Provision for oil draining

Necessary provisions for oil draining, in the event of a fire, should be

made by way of oil soak pits. Fire separation walls should also be provided
when necessary.

4.1.4 Assembly of Dismantled components

Various components dismantled for transportation should be duly

assembled.

4.1.5 Main Tank

Keep the main tank in its permanent position of operation. Lock the
rollers to prevent any accidental movement on rails. Draw an oil sample from
the botton of the tank and test it for Break-Down-Voltage (BDV).

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Note this value in ―Commissioning Report‖

4.1.6 Bushing

Clean the bushings and check that there are no hair-cracks or other
damages. Test IR value of each bushing with a 500V Megger. It should be
100 M ohms or greater. Note details of Bushings in the ―Commissioning
Report.‖ Mount all the bushings as described in 2.6. Ensure that the test tap
cap is fully tightened, thus positively grounding the same. Adjust the Arcing
Horn Gaps in accordance with the Insulation Co-ordination Note these
values in the ―Commissioning Report‖.

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4.1.7 Conservator & M.O.G.

Note details of M.O.G. in the ―Commissioning Report‖. If the M.O.G. is

provided with a locking lever, it should be removed. Mount the conservator.
When there is as OLTC its conservator is some times provided separately or
by making a partitioned compartment in the main conservator. OLTC
conservator, if separate, should also be mounted.

4.1.8 Buchholz Relay

Note details of ―Buchholz Relay‖ for the transformer and of ―Oil Surge
Relay‖ for the OLTC in the ―Commissioning Report.‖ Buchholz Relay floats
are tied to prevent transit damage. They should be released. Also if ‗ Test‘
lever is provided, it should be in the working position. Mount the ―Buchholz
Relay‖ and the shut off valves as described in 2.10 Similarly mount ―Oil
Surge Relay‖.

Department of Electrical Engineer A.I.E.T-Jaipur

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Buchholz Relay On Trasformer

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 49

4.1.9 Breathers

Note details of Breathers, in the ―Commissioning Report.‖ If OLTC is

provided, it may have its own separate breather. Note details of these
Breathers also in the ―Commissioning Report‖. Check that the colour of
silica Gel in Main Breather is Blue. Remove the rubber cap closing the
breather pipe and fit the breather. Fill oil in the oil cup and remove the seal
which closes the breather opening. Similarly mount the OLTC breather.

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 50

4.1.10 Radiators

Note the details of Radiators and Radiator Valves in the

―Commissioning Report.‖ Mount the radiators as outlined below:

(i) Radiators are to be assembled only one at time.

(ii) Oil required to fill in the radiators is sent separately in drums. Test oil
sample from each drum for BDV. Ensure it is more than minimum
specified in I.S. 1866 for New Transformer.
(iii) Fill the conservator full using an oil filter machine, if available.
(iv) Clean one radiator externally. Remove blanking plates and clean the
gaskets and radiator flanges. If gaskets are damaged, use spare
gaskets.
(v) If blanking plates are not in position and it is suspected that foreign
material might have entered the radiators, clean them internally by
flushing fresh and clean transformer oil.

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(vi) Oil might seep through the tank side radiator valves and be retained
by the blanking plates. This oil should be collected in a clean
container at the time of removing top and bottom blanking plates.
(vii) Bring the radiator flanges close to the flanges on the tank. Ensure
that tank gasket is in position. Fit by means of bolts, nuts spring
washers etc.
(viii) Open the bottom radiator valve using the operating handle. Gradually
unscrew the air release plug on the top of the radiator, until air starts
escaping. Air release plug should not be removed from the engaging
threads as it would be difficult to control oil coming out of it. Oil from
main tank will now flow in the radiator, driving out air form air
release plug. When oil comes out steadily form the air release plug
and no more air comes through, close the air release plug. Open the
top radiator valve. Oil level in the conservator would now have fallen.
Check that there is no oil leakage from the radiator itself and the
gasketted joints. Restore the oil level and assemble the next radiator
in the same manner.

Assembly of radiators should be preceded in only one direction-

clockwise or anticlockwise. After filling last radiator, oil level in conservator
should be restored only up to the filling mark.

When OLTC compartment is provided in the main conservator, this

compartment is to be separately filled up to its filling mark.

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4.1.11 Marshalling Box

Marshalling box should be fitted in position. Pockets of O.T.I. & W.T.I.

should be filled with transformer oil. Bulbs of O.T.I. & W.T.I. should be fitted
in position in their respective pockets.

Set the ‗Alarm‘ & ‗Trip‘ contacts of O.T.I & W.T.I. at required values.
O.T.I. setting as A=85 C & T=95 C W.T.I. setting of A-95 C & T+ 105 C are
considered good. They can be worked out to suit local conditions.

4.1.12 Cable Box

When Cable Boxes are provided they should be mounted and cable
terminations done. Oil filled cable-boxes should be duly filled with oil. In
case of ―Bus-Duct‖ connections, transformer is provide with a flange to
receive the bus-duct. Due connection and fitting should be done to over-
head line by a terminal connector.

4.1.13 Other fittings

Note the details of other important fittings like fans in the

―Commissioning Report‖ and mount these fittings.

4.1.14 Oil Sampling & Filtrations

Taking usual precaution, draw oil samples from Bottom & Top of
main tank and from OLTC. They should be tested for BDV. If they meet the
requirements of I.S. 1866 for new transformers, no further processing is
required. However if they do not meet the requirements, oil needs to be
filtered till the required BDV is obtained. Note the BDV values in the
―Commissioning Report‖.

4.1.15 Air Release

Release air by slowly unscrewing Air Release Plugs provide at

Bushings, Bushing Pockets, Buchholz Relay, Main Tank Cover, Oil Surge
Relay etc. From plain porcelain bushing of 11, 22 & 33 KV, air can be
released by loosening the nut pressing the rubber gasket and pressing the
metal part down.

Department of Electrical Engineer A.I.E.T-Jaipur

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4.2 Commissioning

4.2.1 Pre Commissioning Test

Prior to energizing the transformer, several pre-commissioning test

are done. The objective of these tests is confirm that the transformer has not
suffered damage during transit and also to check any inadvertent slips in
the factory tests, or supply.

4.2.2 Ratio Test

Ratio between all the three corresponding H.V. & L.V. phases is to be
measured on all taps. It is desirable to do this test by a Ratio-meter. But if it
is not available, a simple test of measuring voltages can also serve the
purpose.
Referring to R&D plate, fine out which terminals of H.V. & L.V.
correspond to one phase e.g. for a vector Group of Dyn-11, H.V. Terminals
1U, 1V, & L.V. terminals 2U, 2N correspond to U phase. Apply single phase,
415 V or 240 V, AC., 50 Hz to H.V. side and measure voltage on the L.V.
side. Measure these voltages on all taps and note them in ―Commissioning
Report‖ Repeat for the other two phase. These observations should indicate a
consistent trend of variation in line with the details given in R&D Plates.
Numerical values should approximately check with the voltage ratio

4.2.3 Vector Group Check Test

Connect terminals 1U, 2U together. Apply 3 phase, 415 V, 50 Hz. AC.

To H.V. terminals 1U, 1V, 1W. Measure voltages between terminals 1V-2V,
1V-2W & 1W-2V, 1W-2W (or suitable other voltages if required). Check that
the measured Voltages confirm the relative position of H.V. & L.V. vector
group. For vector group Dyn-11.
H. V. & L.V. vectors are shown independently positioned for Dyn-11,
For the condition 1U & 2U connected together, L.V. Vectors are redrawn as
shown. With this configuration, Voltages 1V-2V & 1V-2W will be equal while
1W-2V will be greater than 1W-2W.
The method can be extended to any other Vector Group. Note the
observations in the ―Commissioning Report‖.

Department of Electrical Engineer A.I.E.T-Jaipur

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4.2.4 Magnetising Current Test

Apply 415 volts, 2 phase, AC. to the H.V. terminals, keeping the L.V.
terminals open and tapping switch in the normal position. Measure the 3
line currents, if possible simultaneously, otherwise one after the other.
Because the 3 phases of the magnetic circuit of the core are not similar, the
3 line currents will be approximately equal & v phase current around 80% of
either of them. If H.V. is delta connected, V & W phase currents will be
approximately equal and U phase current around 110 %
In case of Power Transformers, such a test is done, some times, along
with routine tests at the manufacturer works. When done at site and results
compared with the factory test confirms that there are no transit damages to
the core and windings. Note the observations in the ―Commissioning Report‖.

4.2.5 Magnetic Balance Test

This is a simple test to detect shorted turns is a winding. Its principle

is that shorted turns oppose establishment of flux in that limb because of
the current that circulates through the shorted turns.
As indicated in 3.3.2 apply single phase, 415 or 240 V. A .C. to such
H.V. line terminals which would energies U phase. (outer limb) Use an
averaging instrument like a Multimeter Measure the voltages induced in the
V phase (Centre limb and W phase (other outer lime). Measure also the
current drawn by the energized phase. In case the H.V. Voltage is 66 KV and
above, the current drawn may be very small. In that case L.V. would,
generally, be 11 KV or more. This test can, then, be carried out on L.V. Side.
Centre limb being nearer to the energized limb, more flux passes through it
and less flux in the outer limb. The division is around 70-30 % & hence the
measured voltages will be having approx this proportion. Next, energies W
phase and measure the other two voltages as before. Results should be
similar to previous ones. Then energies V phase (Centre limb). As both the
outer limbs are symmetrically located W.R.T. centre limb, flux will divide
equally between them. Hence the voltages measured on outer phases will be
approx. equal. Also, for reasons explained earlier, currents drawn when
outer phases are excited will be equal that for centre phase will be less
(approx. 70 %). Thus these observations will confirm the healthiness of the
windings.
In case one of the phases has shorted turns, it will draw a
comparatively large current when it is energized. When other phases are
energized, flux and hence voltage in the shorted phase will be significantly
reduced. Hence all three observations will indicate the shorted phase. Note
the observations in the ―Commissioning Report‖.
When the Magnetic Balance Test indicates a shorted phase,
commissioning can not be undertaken. Contact us immediately giving
detailed test results.

Department of Electrical Engineer A.I.E.T-Jaipur

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4.2.6 Measurement of Insulation Resistance

Measure Insulation Resistance (IR) between windings and between

windings and earth with a 2500/1000V Megger, preferably motor driven
otherwise hand-driven. Before measuring I.R., thoroughly clean all the
bushings with clean cotton cloth, if required using Carbon Tetrachloride.
Also, there should be no external connections to the transformer terminals.
Check and adjust, if required, the infinity setting of the Megger. Lead wires
from the Megger to the transformer should run independently and be
permanently clamped. They should not have any joints. It is known that the
I.R. reading continues to increase initially and for comparison purpose,
reading continues to increase initially and for comparison purpose, reading
is to be taken at 1 minute of energizing. It is also known that I.R. value is
dependent on temperature. Hence temperature at the times of measurement
should be noted. Compare the I.R. values measured, with the Factory results
keeping in view the temperature at the time of measurement. Note the
observations in ―commissioning Report‖. Also measure and note the I.R.
values of the power Cable.

Department of Electrical Engineer A.I.E.T-Jaipur

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4.2.7 Short-Circuit Test

For the H.V. side voltage and the % impedance, it would be possible to
calculate the current which would flow in the H.V. side, with 415V applied to
it, while keeping L.V. side shorted. If the 415 V source can feed that current,
a short-circuit test can be carried out.
This test would confirm proper contact engagement at all tap
positions. Apply 3 ph. 415 V, 50 Hz to H.V. side, keeping L.V. side shorted.
Measure the 3 line currents at all tap positions. If the switch is an OFF-
CIRCUIT switch, supply has to be disconnected before changing tap. Note
the observations in the ―Commissioning Report‖. Note also details of OLTC, if
any.
A Consistent trend indicates healthiness. If short-circuit test is not
possible due to limitation of source, carry out one tap changing operation
over the entire range increasing as well as decreasing. Check the other
modes of OLTS operation and note in ―Commissioning Report‖.

4.2.8 Parallel Operation

Sometimes the transformer to be commissioned is required to run in

parallel with an existing transformer. In is case, the following conditions
must be fulfilled by the incoming transformer.

(1) Its voltage ratio is same as the existing transformer on all tappings.
(2) Its % Impedance is within +1% of value of existing transformer.

NOTE: Due to difference in % impedances, when one transformer

reaches its rated load, the other would share less than its rated load. As a
result, the combination can supply load less than the sum of the two KVAs.

(3) Rated KVAs of the two transformers to be connected in parallel should

not differ by more than 1:3 as otherwise only marginal increase will be
obtained in the capacity of the combination.
(4) Vector group is compatible. If the vector groups of the two are such that
terminals to be paralleled have a phase different then they can not be
connected in parallel. Hence only certain Vector Groups are compatible
with each other.

If possible, one should check zero voltage between the corresponding

phases to be paralleled.

Department of Electrical Engineer A.I.E.T-Jaipur

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4.3 Other Relevant Details

Other controlling and protecting equipments like C.T.s, Breakers,

relays etc. from a part of the transformer installation. Note their details in
―Commissioning Report‖

4.4 Check Points

After completing installation and pre-commissioning tests, check

that the various points mentioned in the ―Commissioning Report‖ have been
complied with. Compliance nothings should be made in the ―Commissioning
Report‖.

4.5 Energising

When all the pre-commissioning tests are found satisfactory and all
the check points are confirmed the transformer can be energized on No load.
It is preferable to keep settings of all protective relays to the minimum. The
transformer should be allowed to run on No-Load for about 3 hours. During
this period, the transformer should be observed for any abnormality in the
hum and gas collection in the Buchholz Relay. Sometimes during this
period, trapped air is released and gets accumulated in Buchholz Relay.
At the end of this 3 hours period, transformer should be de-energised
and air released from Bushings, Bushing pockets, Buchholz Relay, Main
tank cover, Radiators etc. The transformer should, then, be energized again
and then relays set at their desired setting. Transformer should then be
grandually loaded reaching full load in about 3 hours time. During the
period and for further 3 hours, (i.e. total of 6 hours) transformer should be
under observation. Check that all instruments, O.T.I & W.T.I, M.O.G. are
reading properly and that all radiators are uniformly hot. Check that there is
no gas collection in Buchholz Relay. If everything is found in order, the
transformer can continue working.
The ―Commissioning Report‖ should be duly signed by the Authorised
representatives of all the participating organizations.

Department of Electrical Engineer A.I.E.T-Jaipur

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5 OPERATION & MAINTENANCE

5.1 OPERATION

I.S.2026-1977 states that a Power Transformers loaded at its rated

KVA will fulfill its normal life when its hottest spot temperature [ H.S.T.] is
98˙C for an air temperature of 32˙C As the ambient air temperature exceeds
32˙C the H.S.T. exceeds 98˙C The insulation ageing { which decides the life of
transformer}increased with increase of H.S.T. increase of H.S.T. by 6˙C
doubles the rate of ageing { i.e. reduces the life by 50%}. When the ambient
air temperature is lower than 32˙C the H.S.T. is lower than 98˙C. The
insulation ageing decreases thus increases the life of transformer.
It is considered {by the I.S. 6600-1973} that periods of accelerated
ageing due to higher ambient temperature are compested by the period of
reduced ageing due to lower ambient temperature.
Some times a transformer may be required to deliver load higher than
its rating. Guidance on overloading it provided by I.S. 6600 Basis for the
recommendation is an follows.
In a 24 hours loading. If ambient temperature is low and loaded for a
substantial time duration is also low a short time over load may be
permitted such that equivalent aging due to this varying load will be the
same as that of loading over a period of 24 hours.

5.2 Maintenance

5.2.1 General

Compared to most electrical equipments transformer requires

relatively less maintenance. However in order to obtain a long and trouble
free service from the transformer. It must be properly maintained.
Maintenance consist of regular inspection testing and reconditioning When
necessary. Principal object of maintenance is to maintain the insulation in
good condition. Moisture dirt and high temperature causes insulation
deterioration i.e. ageing. Hence they must be prevented.
No work should be done on the transformer unless It is
disconnected from all external circuits and all windings have been solidly
earthed.
Naked lights and flames should be kept well away from the
transformer.
Precautions must be taken to secure tools with tapes to prevent
them from falling inside the tank.
Maintenance hints on main constituents of the transformer are
given in the following paragraph.

Department of Electrical Engineer A.I.E.T-Jaipur

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Recommended frequency of maintenance is given at the end of

the chapter. Detailed guidance on Maintenance is given in I. S. 10028 { part-
II} – 1981.

5.2.2 OIL

In the transformer, oil is used as an insulating liquid as well as for

cooling, It is necessary to maintain required oil level and also to maintain
this oil in good condition I.S. 1866. gives recommendations in details for the
maintenance of oil. A few guide lines are given here.
i. Check if there is any leakage of oil. It noticed, corrective action
must be immediately taken
ii. The oil level should be checked at frequent intervals and if
necessary, topping up should be done with oil complying with
I.S. 335.
iii. Samples of oil should be taken at regular intervals and tested.
iv. If the dielectric strength is below the value recommended in
I.S. 1866, the oil should be duly filtered. It may be noted that
the products of decompositions with, water acids etc. remain
in the oil and accelerate the rate of aging. Thus, timely
treatment of oil is a must. The filteration will remove moisture,
dust sludge etc. Removal of sludge is important as otherwise
it can stick to coils and hamper the heat dissipation from coils.
However if the results indicate that acidity needs to be
improved. Them a simple filteration would not be sufficient
and a Fullers Earth treatment would be required.

5.2.3 Care & Winding

It id recommended that the core and windings are removed from the
tank for visual inspection as per the maintenance schedule given.
Depending upon the arrangement provided, tap switch handle, connections
to bushings etc. may have to be disconnected before lifting up core and
wings assembly
The windings should be examined and if sludge has been deposited
it should be washed away with oil jet. Any loose nut and bolt should be
tighterned.
Adjust the rods/coil clamping screws provided to remove any
slackness of windings. This is important as slackness in winding will
permit movement of coils under the action of Short Circuits forces and
repeated coil movement can wear out insulation and give rise to a fault.

Department of Electrical Engineer A.I.E.T-Jaipur

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5.2.4 On Load Tap Changer

On load tap changer is, normally, mounted on the tank in the

separate housing and connected to winding leads through copper studs fixed
on insulated terminal board. Terminal board is oil-tight. Hence oil in the
tank need not be lowered for attending O. I. T. C.
In some other types O. I. T. C. is housed in the main tank by suitable
mounting on the top cover Here again O.L.T.C. oil in which arcing tanks
place is not allowed to mix with the man tank oil.
Please refer to O.L.T.C. menual for operation and maintenance
instruction of O.L.T.C.

5.2.5 Conservator & Oil level Indicator

The Inside of conservator should be cleaned by flushing , clean

Transformer oil to remove sluge and other impurities. In bigger transformers,
detachable end plate is provided to facilitate cleaning of conservator.
Oil gauge glass should be cleaned if then glass is found broken,
the same should be replaced.
Magnetic oil guage to be attended while cleaning the conservator.
The mechanism should be inspected and cleaned Float should be checked to
see that there is no oil in the float. This operation of alarm and trip contacts
should to be checked.

5.2.6 Silica Gel Dehydrating Breather

Breather should be examined to ascertain if the silica gel requires

changing. More frequent inspection are needed when the climate is humid
and when transformer is subjected to fluctuating load. The colour of silica
Gel crystals in the breather acts as an indicator as an indicator as it
changes from blue to pink when saturated with moisture. When majority of
crystal have turned pink. The silica gel should be reactivated by beating in
oven of a shallow pan at a temperature of 150‘C to 200‘C until the original
colour is gained. This usually takes 2 or 3 hours. Oil cup should be cleaned
to remove dust and dirty oil. Oil seal should be filled with fresh oil.

5.2.7 Buchholz Relay

Routine operation and mechanical inspection should be carried out as

per the manufacturing instruction.

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5.2.8 Pipe work

The pipe work should be inspected for leakages, which may be due, to
bad seated joints, joints should be re-made and leakage stopped.

5.2.9 Explosion Vent

The diaphragm at the exposed end of the exposion vent should be

inspected and replaced if damaged Failure to replace the diaphragm quickly
may allow the ingress of moisture in the transformer,
Whenever button diaphragm ruptures. Oil rises inside the explosion
vent pipe and visible in the oil level indicator on explosion vent. It diaphragm
is broken because of fault in the transformer. Inspection should be carried
out to determine the nature and case of their fault.

5.2.10 Bushing

Porcelain insulators should be cleaned and minutely examined for

any cracks, chipping off & other defects. All such bushings should be
replaced. In case of any sign of oil leakage from the condenser bushings the
matter should be referred to us.

5.2.11 External connections Include Earthing

Check all external electrical connections including earthing. They

should be tight. If they appear blackened or corroded, unbolt the connection
and clean with emery paper. Remake the connections and give a heavy
coating of conducting grease. It is particularly important that heavy current
carrying connections are properly made as any loose connections give rise to
eat generation & temperature rise which could be detrimental to the
connection.

Department of Electrical Engineer A.I.E.T-Jaipur

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5.3 OTHER PROTECTIVE EQUIPMENT

5.3.1 CURRENTTRANSFORMER

Protective transformers include current transformer and voltage

transformer.
The relays are connected in the secondary circuit of protective
transformer. The stand and secondary voltage circuit of protective
transformer. The standard voltage of current transformer is either
transformer is 110 v. between phase and 63.5 between phase and neutral.
The burden of protective transformer is specified in volt amp at rated
secondary current at specified the power factor.
The accuracy of protective transformer is specified by classification
based on limits of ratio error and phase error.

5.3.2 POTENTIAL TRANSFORMER

There are too types of construction electromagnetic VT & CVT. CVTs

are used for voltage above 66 KV.
Transient performance of VTs is important in protection. CVT should
not given Ferro resonance & secondary over voltage. Electromagnetic is
superior to CVT in respect

5.3.3 LIGHTENING ARRESTER (gap less zone)

Zinc oxide gapless arresters or metal oxide arrester. There are gapless
& consist of zinc-oxide dises in series zone arresters have. Superior V/I
characteristic & higher energy absorption level and they are preferred for
EHV & HVDC installations.

For protective converter equipment from DC side surges have the

different criteria as compared with A.C application. The D.C arrester should
be suitable for operation in inductive circuit & capable of discharging.
Relative long duration has to take place without oil of zero passages. To
fulfill such requirement & to provide low protective levels special design of
active gap is necessary zone arrester with active gaps are used. These have
superior characteristic & high discharged capability.

Department of Electrical Engineer A.I.E.T-Jaipur

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5.4 Prevention Maintenance of Transformer

The normal life of a well operated transformer may be taken as 25-35

years.
It may serve longer if careful installation rigid inspection & preventive
maintenance is carried out the following points need consideration.

5.4.1 Over heating

Over heating damages the installation the amount of defrerioration

depends on the degree of over heating & length of time duration, the damage
also occurs due to mechanical means such as vibration or movement of
transformer. In some case transformer may burst in to flames the oil when
overheated, forms sluge, which is deposited on the winding & tends to clog
the cooling ducts.

5.4.2 Impurities

Impurities in the reduce its insulating properties & speeds up

slugging the moisture is absorbed by the paper from the atmosphere
through the oil.

5.4.3 Mechanical damage

The connections may become loose or dirty. The porcelain of bushing

may gate cracked or chipped.

5.4.4 Frequency of Maintenance

It is necessary to check the various parts at comparatively short

intervals.

5.4.5 Breather

Change in weather or in load cycle may increase the intake of

moisture considerably & therefore it becomes necessary to attend the
breather move frequently per month.

Department of Electrical Engineer A.I.E.T-Jaipur

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5.4.6 Oil

The oil in high voltage transformer needs testing twice in week.

5.4.7 Temperature

When the transformer is installed & put in service for the first time,
the oil temperature must be taken at interval of about 2 hours for the first
two days.
The temperature of oil may than be checked for further 2 or 3 days
during these hours to see whether the same temperature is reached every
day. If the temperature remains below 70`c the temperature may be checked
one 9 month or so unless the load increases or weather gats considerable
hot. In case of temperature exceeds 70`c more frequeat checking of
temperature is required.

5.4.8 Complete over hall

From time to time the transformer should be taken out of service for a
complete examination & over hall, which should include lifting or core &
winding from the tank for inspection.

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5.5 MAINTENANCE SCHEDULE

Recommended maintenance schedule is given below. However,

depending on the local situation and importance of transformer, frequency
my be increased.

SI. Inspection Items to be Inspection Action required

No. Frequency Inspected Notes inspection shows
Unsatisfactory
conditions.

1 2 3 4 5

1. Hourly (i) Ambient - -

(ii) Winding Check that Shut down the

Temp. temp. transformer and
investigate

(iii) Oil Rise is If either is

Temperature reasonable persistently higher
than normal.

(iv) Load Check against Control load.

(amperes)

2. Daily (i) Oil level Check against If low, top up with

in transformer oil dry oil, examine
Transformer temperature. transformer for
on load tap leaks.
changer

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MANUFACTURING OF TRANSFORMER 66

(ii)
Explosion
- Replace if cracked or
vent
broken.

(iii) Check color of If silica gel is pink

ehydrating the active agent change by spare
breather and that charge.
opening is not
The old charge may
clogged.
be reactivated for
further use.

3. Quarterly (i) Bushing Examine for Clean or replace as

cracks and dirt necessary.
deposits.

(ii) Oil in Check for Take suitable action

Transformer dielectric to restore quality of
And tap trength and oil.
changer. water content.

(iv) On load Check oil.

tap
-
chang
er

driving

mecha
nism.

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 67

(v) On load Check all -

tap circuits
changer independently.
automa Check step by
tic step operation
control. including limit
switches.

(vi) Check oil level Make up oil if

Dehydrating in oil cup. required.

breather.

(vii) Check -
Ventilators that air
passages are
(In
free.
case of
indoor
transformers)

4. Yearly (i) Oil Check Filter or

in the acidity replace.
(or earlier
transfo
if
rmer
transforme
and
r can
sludge.
convenient
ly be taken
out for
checking)

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 68

(ii) Compare Process if

Insulation with values at required.
the time of
Resista
commissioning.
nce

(iii) Tighten the

Gasketted bolts evenly to
avoid uneven
joints.
pressure.

(iv) Check Replace

Cable Boxes. for sealing gaskets, if
arrangements leaking.
for filling holes.
Examine
compound for
cracks. Check
moisture
condensate If
any in air filled
boxes.

(v) Examine Clean the

Relay alarms, real and alarm components or
contacts and replace contacts
their
their operation and fuse, if
circuits,
fuses, etc. necessary change
etc.
Check relay the setting if
accuracy, etc. necessary.

(vi) Pockets Oil to be

Temperature holding replenished, if
thermometers required.
Indicat
should be
or
checked.

(vii) Check Adjust if

Dial type Oil pointer for required.

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 69

Gauge freedom of
movement.

(viii) Should Any

Paint work be inspected. painting or
retouching should
be done if
necessary.

(ix) - Take
Earth suitable action if
earth resistance is
Resista
high.
nce

(x) Examine Clean or

Surge diverter for cracks and replace.
dirt deposits.
and
gap

5. Two (xi) Internal Filter oil

Non- inspection regardless of
years
above care. condition.
conserv
ator

transfo
rmers

-do- (xii) Internal Should be

Coil Inspection thoroughly
cleaned.
Conser
vator

-do- (xiii) Mechani Adjust

Buchholz cal inspection floats, switches
reply etc. as required.

6. 5 (xiv) Overall Wash by

Transformers inspection hosing down with

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 70

years up to 3 including lifting clean dry oil.

MVA of core and
Tighten coil
coils.
clamping
arrangements and
other bolts, nuts,
if loose.

7. 7 to (xv) -do- -do-

Transformers
10 Years
above 3
MVA

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MANUFACTURING OF TRANSFORMER 71

5.6 Trouble – Shooting

 At the time of commissioning or periodic maintenance if any

abnormalities are observed, corrective action should be taken
immediately.
 Guidance for this is given in I.S. 10028 (part III) - Maintenance.
 For a transformer in service, indication of trouble is given by the
various alarms provided. These alarms must be accepted and
corrective action initiated immediately.
 In the case of a server fault or if alarm is not attended the
transformer is tripped by the Tripping circuits. This is a very
undesirable situation and should, possibly, be avoided.
 If tripping and subsequent investigation indicates internal faults,
transformer has to be taken out of service.

Several other methods of testing to assist preventive maintenance are

available.

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MANUFACTURING OF TRANSFORMER 72

6 CONCLUSION
The training of which manufacturing of transformer company was
very help full to me. It has improved my theoretical concept of transformer.
We also know that a transformer is a device that transfers electrical
energy from one circuit to another through inductively coupled conductors—
the transformer's coils. A varying current in the first or primary winding
creates a varying magnetic flux in the transformer's core and thus a
varying magnetic field through the secondary winding. This varying magnetic
field induces a varying electromotive force (EMF), or "voltage", in the
secondary winding. This effect is called inductive. The training was more
than hope to me and also help me to understand about manufacturing of
transformer more.

Department of Electrical Engineer A.I.E.T-Jaipur

MANUFACTURING OF TRANSFORMER 73

7 Reference
 Basic Electrical Engineering, by R.P. Ajwaliya
Chapter No. 14
Page No.367 to 415

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MANUFACTURING OF TRANSFORMER 74

8 BIBLIOGRAPHY

 www.atlantaeletrcals.com
 http://seminarprojects.com/Thread-construction-of-
transformer
 http://www.most.gov.mm/techuni/media/EP_03041_6.pdf
 http://www.energymanagertraining.com/CodesandManualsCD-
5Dec%2006/BEST%20PRACTICE%20MANUAL-
TRANSFORMERS.pdf
 http://tad-
electronics.com/files/Download/The_J%26P_Transformer_Book
_12E.pdf
 http://www.powerlinker.org/htm/SFRA.pdf
 http://www.powersystemconsultant.com/htm/PARTIAL%20DIS
CHARGE.pdf
 http://www.carroll-
meynell.com/pdf/Cast%20Resin%20Testing.pdf
 http://www.carroll-
meynell.com/pdf/Cast%20Resin%20Testing.pdf

Department of Electrical Engineer A.I.E.T-Jaipur