J.T.

Mahajan Polytechnic, Faizpur

During academic year

2019-2020

Micro Project Report

On

“VISIT ELECTRICAL MACHINE MANUFACTURING UNIT

AND COLLECT DATA OF VARIOUS TESTS CONDUCTED ON
IT.”

Has been

Submitted by

1)Deepak Dude 2)ChetanBhoi

3) Vaibhav Bari

Under the guidance of

Dr.S.S.ZOPE
Lecturer
Department of Electrical Engineering
 Maharashtra State Board of Technical Education Mumbai

Department of Electrical Engineering

Submission
We the students of Sixth Semester Electrical Engineering submit the report onMicro Project
work titled as“VISIT ELECTRICAL MACHINE MANUFACTURING UNIT AND COLLECT DATA OF
VARIOUS TESTS CONDUCTED ON IT.”

in the course of Maintanance Of Electrical Equipment(22625)during academic year 2019-20

Under the guidance

of

Mr.Dr.S.S.ZOPE
Lecturer

Department of Electrical Engineering

In the partial fulfillment of Fifth Semester Diploma in Electrical Engineering

Submitted by

1) Deepak Dude 2) Chetan Bhoi

3) Vaibhav Bari.

Maharashtra State Board of Technical Education Mumbai

Technical and Medical Education Society’s

 J T Mahajan Polytechnic Faizpur
Department of Electrical Engineering
(Name of Department)

Certificate
This is to certify that the report on micro project work titled as
“VISIT ELECTRICAL MACHINE MANUFACTURING UNIT AND
COLLECT DATA OF VARIOUS TESTS CONDUCTED ON IT.”

1) Deepak Dude 2) ChetanBhoi

3) Vaibhav Bari

The students of Sixth Semester Diploma in Electrical

Engineering as a part of micro project work prescribed by
Maharashtra State Board of Technical Education Mumbai
in the partial fulfillment of Diploma in Electrical Engineering.

Dr.S.S.ZOPE Dr S.S Zope

Project Guide Head of Department

Principal
Maharashtra State Board of Technical Education Mumbai

Acknowledgement
 First and foremost, we would like to thank God, the Almighty, for nothing is possible
without His will.
We grateful to the invaluable motivation and guidance of my Guide, ShriDr.S.S.ZOPE who
has always been a source of inspiration and encouragement for me. He has been an outstanding
caring person and a guide as well. we express my sincere gratitude for his priceless cooperation
and support throughout the work. He has always been ready to help and guide me in the ups and
downs and his sympathetic comments, reminders and assurance has been a source of inspiration
for me.
My sincere vote of thanks also goes to Head of Department, Shri S S Zope for well-timed
alarming, and keeping me well in contact with the entire system. we am most thankful to his an
extraordinary considerations.
We would like to express my special gratitude to my Honourable Principal Shri P B Patil,
really a man of principle, for providing a motivational ambiance in the completion of my work. we
am so thankful to his kind nature and nourishing attitude.
we would like to acknowledge the support and encouragement of all the faculty members, my
fellows, lab supporting staff and others.

Name of Student Signature

1) Deepak Dude

2) ChetanBhoi

3) Vaibhav Bari

PART A
Plan
Title of Micro-Project:“VISIT ELECTRICAL MACHINE MANUFACTURING UNIT
AND COLLECT DATA OF VARIOUS TESTS CONDUCTED ON IT.’’

1.0Brief Introduction.
The various types of the protective relays are available for protecting the motor from faults. These relays
sense the abnormal operating condition and make the circuit breaker to trip. The motors provide
protection against faults in windings and associated circuits, excessive overload and short circuits, under
voltages, phase unbalances and single phasing, phase reversal and switching overvoltages.
2.0 Aim of the Micro-Project

This Micro-Project aims at

1) To use motor protection scheme for 20HP motor
2) To practice good housekeeping with safety measure
3) To demonstrate working as a leader/ team member
3.0 Action Plan (Sequence and time required for major activities for 8 Weeks)
Sr. Details of activity Planned Plan finish Name of Responsible
no start date date Team Members

1. Discussion on group formation Deepak Dude

Chetan Bhoi
2. Selection of micro-project title
Vaibhav Bari
3. Knowing about the title in detail

4. Collect information regarding the Phase

Transformer Connection

5. Open the Transformer and identify the

component of Transformer

6. Then reassembling the Transformer

7. Testing it once again

8. Report writing

4.0 Resources Required (major resources such as raw material, some machining facility, software
etc.)

SN Name of Resource/material Specifications Qty Remarks

1 Reference book Techmax publication 01

2 Reference book Nirali publication 01
3 Youtube Internet 01
 Teacher Evaluation Sheet

Name of students ; 1) Deepak Dude 1)1700620128

2) Vaibhav Bari 2)1700620131

 3) Chetan Bhoi 3)1700620129

Name of Programme: Electrical Engineering Semester: Sixth

Course Title: Maintanance Of Electrical Equipment Code: MEE (22625 )

Title of the Micro-Project: “VISIT ELECTRICAL MACHINE MANUFACTURING UNIT AND

COLLECT DATA OF VARIOUS TESTS CONDUCTED ON IT.”

Course Outcomes Achieved

To developed basic cognitive skills require to take appropriate decessions to maintain various
generating &auxiliary equipment of power plants
Evaluation as per Suggested Rubric for Assessment of Micro Project

Sr. Characteristic to be assessed Poor Average Good Excellent

No. ( Marks 1 - 3 ) ( Marks 4 - 5 ) ( Marks 6 - 8 ) ( Marks 9- 10 )

1 Relevance to the course

2 Literature Survey / Information

Collection

3 Project Proposal

4 Completion of the Target as per

project proposal

5 Analysis of Data and

representation

6 Quality of Prototype/Model

7 Report Preparation
 8 Presentation

9 Defense

Micro-Project Evaluation Sheet

Process Assessment Product Assessment Total

Part A - Project Project Methodology PartB - Project individual Marks

Proposal (2 marks) Report/Working Presentation/Viva
(2 marks) Model (4 marks) 10
(2 marks)

Note:
Every course teacher is expected to assign marks for group evolution in first 3 columns &
individual evaluation in 4TH columns for each group of students as per rubrics.

Comments/Suggestions about team work/leadership/inter-personal communication (if any)

Improve your communication skill to make better inter-personal communication for
effective co-ordination and co-operation. Read, understand and apply the soft skill
topics to improve your personality.

Any Other Comment:

Focus on micro project work right from first week of semester so as to complete all
activities on time without any bustle.

Name and designation of the Faculty Member:- Mr. Dr.S.S.ZOPE (LEE,0062)

Signature…………………………………………………………………………………………...
 PART B
Plan
When transformers are received from the factory or reallocated from another
location it is necessary to verify that each transformer is dry, no damage has
occurred during shipping, internal connections have not been loosened, the
transformer’s ratio, polarity, and impedance agree with its nameplate, its major
insulation structure is intact, wiring insulation has not been bridged, and the
transformer is ready for service. Physical size, voltage class, and kVA rating
are the major factors that dictate the amount of preparation required to put
transformers in service. Size and kVA rating also dictate the kind and number
of auxiliary devices a transformer will require. All of these factors affect the
amount of testing necessary to certify that a transformer is ready to be
energized and placed in service. There are a multitude of checks and tests
performed as a transformer is being assembled at a substation. The test engineer
may not directly perform all of the following tests and inspections but must be
sure they are satisfactorily completed, so that the final decision over
transformer bank readiness for energization can be made. Some tests and
procedures may be performed by specialists during the assembly phase.
Special tests, other than those listed, may also be required. Many require
special equipment and expertise that construction electricians do not have and
are not expected to provide. Some tests are performed by an assembly crew,
while other tests are done by the person(s) making the final electrical tests on
the transformers.BPA has hundreds of power transformers installed throughout
the system, and few of them are identical. The following information is not
intended to describe, or include, the details for performing the entire array of
tests needed to prepare transformers for service, only the tests that may be
performed by field personnel. Even though details have been limited,
descriptions should allow field personnel to perform, or assist in performing,
the basic tests they may be asked to do. Procedures and tests are described
somewhat generically, but apply to most transformers in one way or another.
Also, the following test descriptions provide an anchor point from which to ask
for help when needed. The following items are discussed or described:

1) Winding resistance test of transformer

2) Transformer ratio test
3) Measurement of insulation resistance 4) Tempreature rise test of
transformer

1)Transformer Winding Resistance Measurement

Transformer winding resistance measurement is carried out to calculate the

I2R losses and to calculate winding temperature at the end of a temperature
rise test. It is carried out as a type test as well as routine test. It is also done at
site to ensure healthiness of a transformer that is to check loose connections,
broken strands of conductor, high contact resistance in tap changers, high
voltage leads and bushings etc.
There are different methods for measuring of the transformer winding,
likewise:

• Current-voltage method of measurement of winding resistance.

• Bridge method of measurement of winding resistance.
• Kelvin bridge method of Measuring Winding Resistance.
• Measuring winding resistance by Automatic Winding Resistance
Measurement Kit.

2)Transformer Ratio Test

The performance of a transformer largely depends upon perfection of specific

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

3)Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in the

magnetic core structure, shifting of windings, failure in between turn
insulation or problem in tap changers. These conditions change the effective
reluctance of the magnetic circuit, thus affecting the current required to
establish flux in the core.
1. Keep the tap changer in the lowest position and open all IV and LV
terminals
2. Then apply three phase 415 V supply on the line terminals for
threephase transformers and single phase 230 V supply on single phase
transformers
3. Measure the supply voltage and current in each phase
4. Now repeat the magnetizing current test of transformer test with
keeping tap changer in normal position
5. Repeat the test while keeping the tap at highest position
6.
Normally, there are two similar higher readings on two outer limb phases
on transformer core and one lower reading on the center limb phase, in the
case of three phase transformers. An agreement to within 30% of the
measured exciting current with the previous test is usually considered
satisfactory. If the measured exciting current value is 50 times higher than the
value measured during factory test, there is a likelihood of a fault in the
winding which needs further analysis.
 • Transformer testing

• Some tests are done at manufacturer premises before delivering the transformer. Mainly two

types of transformer testing are done at manufacturer premises- type test of transformer and

routine test of transformer. In addition to that some transformer tests are also carried out at

the consumer site before commissioning. Type of Transformer Testing:Tests done at factory

1. Type tests 2. Routine tests 3. Special tests Tests done at site 1. Pre-commissioning tests

2. Periodic/condition monitoring tests 3. Emergency tests

Type Test of Transformer

To prove that the transformer meets customer’s specifications and design expectations, the

transformer has to go through different testing procedures in manufacturer premises. Some

transformer tests are carried out for confirming the basic design expectation of that transformer. These
tests are done mainly in a prototype unit not in all manufactured units in a lot. Type test of transformer

confirms main and basic design criteria of a production lot. Type tests of transformer includes : 1.

Transformer winding resistance measurement 2. Transformer ratio test. 3. Transformer vector group

test. 4. Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short

circuit test). 5. Measurement of no load loss and current (Open circuit test). 6. Measurement of

insulation resistance. 7. Dielectric tests of transformer. 8. Tests on on-load tap-changer. 9. Vacuum

tests on tank and radiators.

Routine Tests of Transformer

Routine tests of transformer is mainly for confirming operational performance of individual unit in a

production lot. Routine tests are carried out on every unit manufactured. These tests are: 1.

Transformer winding resistance measurement. 2. Transformer ratio test. 3. Transformer vector group

test. 4. Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short

circuit test). 5. Measurement of no load loss and current (Open circuit test) 6. Measurement of

insulation resistance. 7. Dielectric tests of transformer. 8. Tests on on-load tap-changer. 9. Oil pressure

test on transformer to check against leakages past joints and gaskets. That means Routine tests of

transformer include all the type tests except temperature rise and vacuum tests.

Special Tests of Transformer

Special tests of transformer is done as per customer requirement to obtain information useful to the

user during operation or maintenance of the transformer. 1. Dielectric tests.2. Measurement of zero-

sequence impedance of three-phase transformers 3. Short-circuit test. 4. Measurement of acoustic

noise level. 5. Measurement of the harmonics of the no-load current. 6. Measurement of the power

taken by the fans and oil pumps. 7. Tests on bought out components / accessories such as buchhloz

relay, temperature indicators, pressure relief devices, oil preservation system etc.

Pre Commissioning Test of Transformer

In addition to these, the transformer also goes through some other tests, performed on it, before actual
commissioning of the transformer at the site. The transformer testing performed before commissioning
the transformer at the site is called the pre-commissioning test of transformer. These tests are done to
assess the condition of transformer after installation and compare the test results of all the low voltage
tests with the factory test reports.

Type tests of transformer include:

Winding resistance test of transformer

Transformer ratio test
Transformer vector group test
Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short circuit
test)
Measurement of no-load loss and current (Open circuit test)
Measurement of insulation resistance
Dielectric tests of transformer
Temperature rise test of transformer
Tests on on-load tap-changer
Vacuum tests on tank and radiators
Routine tests of transformer include

Winding resistance test of transformer

Transformer ratio test
Transformer vector group test
Measurement of impedance voltage/short circuit impedance (principal tap) and load loss (Short circuit
test)
Measurement of no load loss and current (Open circuit test)
Measurement of insulation resistance
Dielectric tests of transformer.
Tests on on-load tap-changer.
Oil pressure test on transformer to check against leakages past joints and gaskets
That means Routine tests of transformer include all the type tests except temperature rise and vacuum
tests. The oil pressure test on transformer to check against leakages past joints and gaskets is included.

Special Tests of transformer include

Dielectric tests.
Measurement of zero-sequence impedance of three-phase transformers
Short-circuit test
Measurement of acoustic noise level
Measurement of the harmonics of the no-load current.
Measurement of the power taken by the fans and oil pumps.
Tests on bought out components / accessories such as buchhloz relay, temperature indicators, pressure
relief devices, oil preservation system etc.
Transformer Winding Resistance Measurement
Transformer winding resistance measurement is carried out to calculate the I2R losses and to calculate
winding temperature at the end of a temperature rise test. It is carried out as a type test as well as
routine test. It is also done at site to ensure healthiness of a transformer that is to check loose
connections, broken strands of conductor, high contact resistance in tap changers, high voltage leads
and bushings etc.

There are different methods for measuring of the transformer winding, likewise:

Current-voltage method of measurement of winding resistance.

Bridge method of measurement of winding resistance.
Kelvin bridge method of Measuring Winding Resistance.
Measuring winding resistance by Automatic Winding Resistance Measurement Kit.
Note: Transformer winding resistance measurement shall be carried out at each tap.

Transformer Ratio Test

The performance of a transformer largely depends upon perfection of specific turns or voltage ratio of
transformer. So transformer ratio test is an essential type test of transformer. This test also performed
as a routine test of transformer. So for ensuring proper performance of electrical power transformer,
voltage and turn ratio test of transformer one of the important tests.

The procedure of the transformer ratio test is simple. We just apply three phase 415 V supply to HV
winding, with keeping LV winding open. We measure the induced voltages at HV and LV terminals of the
transformer to find out actual voltage ratio of the transformer. We repeat the test for all tap position
separately.

Magnetic Balance Test of Transformer

Magnetic balance test of transformer is conducted only on three-phase transformers to check the
imbalance in the magnetic circuit.

Procedure of Magnetic Balance Test of Transformer

Keep the tap changer of transformer in normal position.
Now disconnect the transformer neutral from ground.
Then apply single phase 230 V AC supply across one of the HV winding terminals and neutral terminal.
Measure the voltage in two other HV terminals in respect of neutral terminal.
Repeat the test for each of the three phases.
Transformer testing table
In case of an autotransformer, a magnetic balance test of transformer should be repeated for LV winding
also.

There are three limbs placed side by side in a core of the transformer. One phase winding is wound in
one limb. The voltage induced in different phases depends upon the respective position of the limb in
the core. The voltage induced in different phases of a transformer in respect to neutral terminals given
in the table below.

Magnetizing Current Test of Transformer

Magnetizing current test of transformer is performed to locate defects in the magnetic core structure,
shifting of windings, failure in between turn insulation or problem in tap changers. These conditions
change the effective reluctance of the magnetic circuit, thus affecting the current required to establish
flux in the core.
Keep the tap changer in the lowest position and open all IV and LV terminals
Then apply three phase 415 V supply on the line terminals for three-phase transformers and single
phase 230 V supply on single phase transformers
Measure the supply voltage and current in each phase
Now repeat the magnetizing current test of transformer test with keeping tap changer in normal
position
Repeat the test while keeping the tap at highest position
Normally, there are two similar higher readings on two outer limb phases on transformer core and one
lower reading on the center limb phase, in the case of three phase transformers.

An agreement to within 30% of the measured exciting current with the previous test is usually
considered satisfactory. If the measured exciting current value is 50 times higher than the value
measured during factory test, there is a likelihood of a fault in the winding which needs further analysis.

Caution: This magnetizing current test of a transformer is to be carried out before DC resistance
measurement.

Vector Group Test of Transformer

In a 3 phase transformer, it is essential to carry out a vector group test of transformer. Proper vector
grouping in a transformer is an essential criteria for parallel operation of transformers.

There are several internal connections of three-phase transformer are available on the market. These
several connections give various magnitudes and phase of the secondary voltage; the magnitude can be
adjusted for parallel operation by suitable choice of turn ratio, but the phase divergence cannot be
compensated.

So we have to choose a transformer suitable for parallel operation whose phase sequence and phase
divergence are same. All the transformers with the same vector ground have same phase sequence and
phase divergence between primary and secondary.

Before procuring an electrical power transformer, you should ensure the vector group of the
transformer, whether it will be matched with his or her existing system or not. The vector group test of
transformer confirms his or her requirements.

Insulation Resistance Test or Megger Test of Transformer

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

Procedure of Insulation Resistance Test of Transformer

Disconnect all the line and neutral terminals of the transformer
Megger leads to be connected to LV and HV bushing studs to measure insulation resistance IR value in
between the LV and HV windings
Megger leads to be connected to HV bushing studs and transformer tank earth point to measure
insulation resistance IR value in between the HV windings and earth
Megger leads to be connected to LV bushing studs and transformer tank earth point to measure
insulation resistance IR value in between the LV windings and earth
NB: It is unnecessary to perform insulation resistance test of transformer per phase wise in three-phase
transformer. IR values are taken between the windings collectively as because all the windings on HV
side are internally connected together to form either star or delta and also all the windings on LV side
are internally connected together to form either star or delta.

Measurements are to be taken as follows:

For autotransformer: HV-IV to LV, HV-IV to E, LV to E.

For two winding transformer: HV to LV, HV to E, LV to E.
Three winding transformers: HV to IV, HV to LV, IV to LV, HV to E, IV to E, LV to E.
Oil temperature should be noted at the time of insulation resistance test of the transformer, since the IR
value of transformer insulating oil may vary with temperature.
IR values to be recorded at intervals of 15 seconds, 1 minute and 10 minutes.
With the duration of application of voltage, IR value increases. The increase in IR is an indication of
dryness of insulation.
Absorption coefficient = 1 minute value/15 secs. Value.
Polarization index = 10 minutes value/1 minute value.
Dielectric Tests of Transformer
Dielectric test of a transformer is one kind of insulation test. This test is performed to ensure the
expected overall insulation strength of the transformer. There are several tests performed to ensure the
required quality of transformer insulation; the dielectric test is one of them. Dielectric test of the
transformer is performed in two different steps.

First one is called Separate Source Voltage Withstand Test of transformer, where a single phase power
frequency voltage of prescribed level, is applied on transformer winding under test for 60 seconds while
the other windings and tank are connected to the earth, and it is observed that whether any failure of
insulation occurs or not during the test.

The second one is the induced voltage test of Transformer where, three-phase voltage, twice of rated
secondary voltage is applied to the secondary winding for 60 seconds by keeping the primary of the
transformer open circuited.

The frequency of the applied voltage should be double of power frequency too. Here also if no failure of
insulation, the test is successful.

In addition to dielectric tests of transformers, there are other types of test for checking insulation of
transformer, such as lightning impulse test, switching impulse test and partial discharge test.

Induced Voltage Test of Transformer

The induced voltage test of the transformer is intended to check the inter-turn and line end insulation as
well as main insulation to earth and between windings-

Keep the primary winding of transformer open circuited.

Apply three-phase voltage to the secondary winding. The applied voltage should be twice of the rated
voltage of secondary winding in magnitude and frequency.
The duration of the test shall be 60 seconds.
The test shall start with a voltage lower than 1/3 the full test voltage, and it shall be quickly increased up
to the desired value.
The test is successful if no breakdown occurs at full test voltage during the test.

Temperature Rise Test of Transformer

Temperature rise test of transformer is included in type test of transformer. In this test, we check
whether the temperature-rising limit of the transformer winding and oil as per specification or not. In
this type test of the transformer, we have to check oil temperature rise as well as winding temperature
rise limits of an electrical transformer.