VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“Jnana Sangama”, Belagavi, Karnataka-590018

A Report on Internship (18EEI85)

Carried out at “Kirloskar Electric Co. Ltd, Mysore”

On

“TRANSFORMER MANUFACTURING, TESTING AND

MAINTENANCE”

Submitted in Partial Fulfillment for the Award of Degree

BACHELOR OF ENGINEERING IN ELECTRICAL AND ELECTRONICS

By
BHARATH N (4NN20EE005)

Internal Guide
MR. SRINIVAS S
Assistant Professor, Dept of EEE
NIEIT, Mysuru

External Guide
SRI. SOMASHEKARAPPA T B
HOD Plant Engineering
Kirloskar Electric Co. Ltd, Mysuru - 570018
 NIE INSTITUTE OF TECHNOLOGY
#50 (part), Hootagalli Industrial area, Koorgalli Village, Mysuru-18

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING

CERTIFICATE

This is to Certified that the Internship Report is Carried out at “Kirloskar Electric Co. Ltd,
Mysore” Submitted by Bharath N (4NN20EE005) a bonafide student of NIEIT, Mysuru
in partial fulfillment for the award of Bachelor of Engineering in Electrical and Electronics
of the Visvesvaraya Technological University, Belgaum during the year 2023-2024. The
Internship report has been approved as it satisfies the academic requirements in respect of
Internship work prescribed for the said Degree.

Signature of Internship Signature of HOD Signature of Principal

Coordinator

External Viva

Name of the examiners Signature with date

1.

2
 DECLARATION

We, by Bharath N (4NN20EE005) student of VIII semester, Department of Electrical

and Electronics Engineering, NIE Institute of Technology, Mysuru declare that we
successfully completed the Internship Programme at “Kirloskar Electric Co. Ltd,
Mysore”. This Internship Report Work is submitted to Visvesvaraya Technological
University, Belgavi-590018, in partial fulfilment of the requirements for the award of
Degree of Bachelor of Engineering in Department of Electrical and Electronics
Engineering during the academic year 2023-2024.

Student Signature
Bharath N
4NN20EE005
 ACKNOWLEDGEMENT

We sincerely thank Smt. Jyothi B M, HR at Kirloskar Electric Co. Ltd, Mysuru, for
providing us an internship opportunity.

Our deepest gratitude to Sri. Somashekarappa T B, HOD Plant Engineering at Kirloskar

Electric Co. Ltd, Mysuru, for his valuable guidance and support during our internship. We
stand indebted to him for his boundless enthusiasm in ensuring us through understanding
of every concept and for tirelessly clearing our doubts at every stage. His dedication has
been an inspiration, and for that, we are truly thankful.

We're also grateful to Dr. Rohini Naga Padma, Principal at NIE Institute of Technology,
Mysuru, for her support in our academic endeavors.

Special thanks to Dr. Sandeep Kumar K J, Associate Professor & HOD, Department of
Electrical and Electronics Engineering at NIE Institute of Technology, Mysuru. And
Mr. Srinivas S, Internship Coordinator and Assistant Professor at NIE Institute of
Technology, Mysuru, for their advice and suggestions at various stages of work.

Lastly, we extend our thanks to our parents, friends, and Kirloskar Electric Co. Ltd,
Mysuru, for their unwavering encouragement, without which this internship wouldn't have
been possible.
 TABLE OF CONTENTS

1. INTRODUCTION....................................................................................1
1.1 INTERNSHIP OVERVIEW …............................................................................. 1

2. COMPANY PROFILE ............................................................................ 3

2.1 ABOUT COMPANY … ........................................................................................ 3
2.2 HISTORY… .......................................................................................................... 4
2.3 VISION & MISSION ............................................................................................. 5
2.4 QUALITY POLICY ............................................................................................... 5
2.5 PRODUCTS ...........................................................................................................6
2.6 COMPANY GLOBAL NETWORK… ................................................................. 7
2.7 MANUFACTURING PLANT .............................................................................. 7

3. TRANSFORMER..................................................................................... 9
3.1 INTRODUCTION… .............................................................................................. 9
3.2 PRINCIPLE OF TRANSFORMER .......................................................................9
3.3 TYPES OF TRANSFORMER ............................................................................. 10
3.4 PARTS OF TRANSFORMER ............................................................................. 16
3.5 MANUFACTURING OF TRANSFORMER ..................................................... 22
3.6 TESTING OF TRANFORMER ........................................................................... 24
3.7 VECTOR GROUP OF TRANSFORMERS ......................................................... 30
3.8 MAINTENANCE OF TRANSFORMER ............................................................ 36
3.9 PROTECTION OF TRANSFORMER................................................................ 36
3.10 FAILURE & CAUSES OF TRANSFORMER ................................................... 37

4. KEY LEARNINGS................................................................................ 38

5. CONCLUSION ..................................................................................... 40
 1. INTRODUCTION

1.1 INTERNSHIP OVERVIEW

Exploring Transformer Manufacturing at Kirloskar

During the span of one month, I had the privilege of embarking on an enriching internship
journey at Kirloskar, a renowned name in the realm of electrical engineering and transformer
manufacturing. This immersive experience provided a unique opportunity to delve into the
intricate processes involved in crafting transformers, essential components in the realm of power
distribution and transmission.

At Kirloskar, I was exposed to the entire spectrum of transformer manufacturing, from inception
to execution. The internship commenced with an in-depth orientation to the fundamentals of
transformer design, emphasizing key parameters such as voltage ratings, load capacity, and
efficiency. This foundational knowledge laid the groundwork for subsequent activities and tasks
throughout the internship tenure.

One of the most rewarding aspects of the internship was the hands-on learning experience
offered within Kirloskar’s state-of-the-art manufacturing facilities. Under the guidance of
seasoned professionals, I actively participated in various stages of transformer production,
including core fabrication, winding, insulation, and assembly. This practical engagement not
only honed technical competencies but also instilled a profound appreciation for precision and
quality in manufacturing processes.

Throughout the internship, I had the privilege of interacting with experts in the field, including
design engineers, production supervisors, and quality assurance specialists. These interactions
provided invaluable insights into industry best practices, emerging trends, and real-world
challenges encountered in transformer manufacturing. Engaging in discussions and knowledge-
sharing sessions enriched my understanding of the subject matter and broadened my perspective
on the intricacies of the engineering profession.

Beyond technical skill development, the internship at Kirloskar fostered holistic professional
growth. Collaborating with multidisciplinary teams, I honed communication, teamwork, and
problem-solving skills essential for navigating complex engineering projects.

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Moreover, exposure to the corporate environment instilled a sense of responsibility,
accountability, and professionalism, attributes crucial for success in any professional endeavour.

In conclusion, the internship experience at Kirloskar was a transformative journey that provided
a comprehensive insight into the realm of transformer manufacturing. From theoretical concepts
to practical applications, each facet of the internship contributed to personal and professional
growth, equipping me with the knowledge, skills, and confidence to excel in the field of
electrical engineering. I am deeply grateful to Kirloskar for the opportunity and look forward to
leveraging this invaluable experience as I embark on my engineering career journey.

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 2. COMPANY PROFILE

2.1 ABOUT COMPANY

Kirloskar Electric Company Limited, in Mysore,

Karnataka, India, holds a prominent position within the
manufacturing landscape. As a subsidiary of the
renowned Kirloskar Group, an established company
known for its expanded business interests, Kirloskar
Electric's core focus lies in the production of electrical
equipment, with a special emphasis on transformers and
switchgear solutions.

This company boasts a storied history back to its beginning in 1946, a testimony to its enduring
legacy in the electrical engineering industry. Over the years, Kirloskar Electric has carved out a
role for itself as a leader in its field, consistently upholding the values of quality, reliability, and
sustainability in the manufacturing of electrical components.

One of the critical roles this company plays is in supplying essential equipment for power
distribution and control systems. By doing so, Kirloskar Electric contributes significantly to the
development of India's industrial infrastructure. Its products are integral to ensuring the efficient
and safe distribution of electrical energy.

Moreover, Kirloskar Electric's reputation for excellence is underscored by its unwavering

commitment to ethical business practices.

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2.2 HISTORY

Laxmanrao. K. Kirloskar
Founder, Kirloskar Group of Companies Shri
Laxmanrao Kashinath Kirloskar was a successful
industrialist. His chief merit lay in the trail he blazed, for
the principles in life he depended upon were his vision and
a spirit of pioneering.

Ravi. L. Kirloskar
Founder, Kirloskar Electric Company Limited
Shri Ravi. L. Kirloskar was the youngest son of Laxmanrao
and Radhabai Kirloskar. Having a degree in electrical
engineering. he began his professional career at Kirloskar
Brothers Ltd. In 1942, he designed and built India's first
electric motor at Kirloskarvadi with his colleague N.K.
Joshi. He went on to head Kirloskar Electric, and guided the
company to the highest levels of excellence.

Kirloskar Electric Company Ltd. is one of the leading Indian electrical engineering companies.
Established in 1946, Kirloskar Electric was the catalyst for industrialization in India. Kirloskar
Electric produces more than 70 products under eight product groups. they cater to core economic
sectors such as power generation, transmission & distribution, transportation, and renewable
energy, to name a few.

The Kirloskar Electric organization comprises nine manufacturing locations and 34 sales offices
spread across the country. they have a large network of spare parts dealers and service centers.
This enables to provide premium products, exemplary systems & services at competitive rates to
our clients. Their products are known for their high quality, durability, and reliability. This is due
to emphasis on design, engineering, and manufacturing. they adhere to international standards by
acquiring & adapting latest technologies along with in house R&D.

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Kirloskar Electric work involves
An installed base of 3 million motors in
• Petrochemicals • Fertilizer
• Refineries • Cement plants
• Steel • Agro based industries
• Aluminum
They have supplied over 15,000 MVA transformers operating in the T&D network. Their
manufacture transformers up to 100 MVA 220 kV for utilities, captive, & industrial users.

They have delivered traction electrics, power car generators, and batteries to Indian Railways.
Kirloskar Electric products and services are availed by the following industries
• Power • Agriculture
• Sugar • Oil & Gas
• Steel • Refineries
• Cement • Nuclear

2.3 VISION AND MISSION

The Power of Now is the energy of opportunities that comes to us disguised as challenges. The
Power of Now at Kirloskar Electric is the dynamic of making opportunities work as by meeting
clients' tough specifications of cost competitiveness, quality, and reliability.

2.4 QUALITY POLICY

The quality policy of Kirloskar Electric Company shall be to design, manufacture, and market at
competitive prices products of such quality, which result in customer satisfaction, quality
reputation, and market leadership.
• Market products and services that exceed the customer needs and expectations
• Operate reliable processes and manage them through trained personnel and effective
Quality Management Systems
• Drive continuous improvement of all business processes towards intended goal

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2.5 PRODUCTS

• AC MOTOR • ELECTRONICS
AC DRIVES, DC DRIVES, BATTERY CHARGES,
UPS

• SWITCH GEARS
• AC GENERATOR

• DC MOTORS • TRACTION

• TRANSFORMERS
• DC SETS

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2.6 COMPANY GLOBAL NETWORK

2.7 MANUFACTURING PLANT

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An Overview of Basic Generating, Transmitting and Distribution Line

220kV / 11kV

3ϕ Phase

220V
Phase

Substation is a part of an electrical generation,

transmission, and distribution system.
Substations transform voltage from high to low,
or the reverse, or perform any of several other
important functions, generally have switching,
protection and control equipment, and
transformers.

Transmission lines are used to connect

power stations and substations, and for
connections between substations, in order to
efficiently transmit large amounts of
electricity at high voltage.

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 3. TRANSFORMER
3.1 INTRODUCTION ABOUT TRANSFORMER

Transformer is a static device that transfers

electric energy from one alternating current
circuit to one or more other circuits through
electromagnetic induction with desired
voltage and current either increasing
(stepping up) or reducing (stepping down) the
voltage. without changing frequency, It plays
a fundamental role in the generation,
transmission, and distribution of electricity.

In a transformer, when a load is connected to the secondary, current flows in the secondary
winding, transferring electrical energy from the primary circuit. In an ideal transformer, the
secondary voltage (Vs) is proportional to the primary voltage (Vp) based on the turns ratio
(Ns/Np).

3.2 PRINCIPLE OF TRANSFORMER

Transformers operate on the principle of electromagnetic induction, discovered by Michael

Faraday. When an alternating current (AC) flows through one coil (known as the primary
winding), it generates a changing magnetic field around it.

This changing magnetic field induces a voltage in another coil (known as the secondary winding)
that is in close proximity. The induced voltage depends on the turn’s ratio between the primary
and secondary windings.

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3.3 TYPES OF TRANSFORMERS

• Distribution Transformer • Locomotive Transformer

• Power Transformer • Mining Transformer
• Current Transformer • Phase Shifting Transformer
• Potential Transformer • High Voltage testing
• Furnace Transformer Transformer
• Welding Transformer • Grounding Transformer
• Booster Transformer • Dry Type Transformer
• Rectifier Transformer • Converter Transformer

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3.3.1 DISTRIBUTION TRANSFORMER
Distribution transformer is a specialized type of electrical
transformer used in power distribution systems to step down
high voltage electricity (11kV) from the transmission system
to lower voltage levels (440V/220V) suitable for residential,
commercial, and industrial use that designed to be highly
efficient to minimize energy losses during the voltage
conversion process. They often have efficiency ratings
exceeding 95%.
IS Rating: in India often comply with IS 1180 and IS 2026

3.3.2 POWER TRANSFORMER:

Power transformers are used in substations to step

up or step-down voltage levels as needed in power
generation, transmission, and large industrial
applications. They are crucial for efficiently
transmitting electricity across long distances. It
plays a central role in the efficient and safe
transfer of electrical power from generating
stations to substations

IS Rating: Power transformers in India adhere to IS 2026 specifications.

3.3.3 CURRENT TRANSFORMER (CT):

Current Transformer (CT) is a critical component in

electrical measurement, protection, and control
systems. It is designed to transform high currents in
power systems into proportional, manageable, and
safe currents for measurement and protection devices.

IS Rating: CTs in India often comply with IS 2705

specifications.

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3.3.4 POTENTIAL TRANSFORMER (PT):

Potential transformers also known as a voltage transformer, are used to

step down high voltages to safer levels for measurement and protection
purposes. They are commonly used in conjunction with instruments and
relays.

IS Rating: PTs in India may adhere to IS 3156 specifications.

3.3.5 FURNACE TRANSFORMER:

Furnace transformers are specially designed for

electric arc furnaces in steel mills and other
industrial applications. They handle high
current and provide the necessary power for
melting metals and refining metals in the
electric arc furnace process which are
commonly employed in the steel and
metallurgical industries

IS Rating: Furnace transformers follow IS 2026

specifications.

3.3.6 WELDING TRANSFORMER:

Welding transformer is a type of electrical transformer

specifically designed for use in welding applications.
Welding transformers are essential components in
various welding processes, and they serve the purpose of
providing the necessary electrical current and voltage to
create an arc between the welding electrode and the
workpiece.

IS Rating: These transformers typically adhere to IS

1851.

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3.3.7 BOOSTER TRANSFORMER:

Booster transformers are used to increase voltage levels

in electrical systems, these transformers are commonly
used in distribution networks to compensate for voltage
drop that occurs over long distances between substations
and end-users. Booster transformers play a crucial role in
maintaining the quality and reliability of electrical power
supplied to consumers.

IS Rating: These transformers typically adhere to IS

2026.

3.3.8 RECTIFIER TRANSFORMER:

Rectifier transformer is a specialized type of transformer

designed for the purpose of supplying direct current (DC)
power from an alternating current (AC) source. It plays a
crucial role in various applications where a steady DC voltage
is required, such as in industrial processes, electrochemical
operations, and high-voltage DC transmission systems.

IS Rating: Rectifier transformers may conform to IS 2026

specifications.

3.3.9 LOCOMOTIVE TRANSFORMER:

A locomotive transformer is a specialized type of

transformer used in electric locomotives to convert
high-voltage alternating current (AC) from
overhead lines or third rails into the lower-voltage
AC needed to power the locomotive's traction
motors. These transformers are essential
components in electric rail systems, allowing trains
to operate efficiently and effectively.

IS Rating: Locomotive transformers generally

follow IS 2026 specifications.

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3.3.10 MINING TRANSFORMER:

Mining transformers are specialized transformers

used in mining operations to provide electrical
power for various equipment and machinery in
both underground and surface mining
environments. These transformers are designed to
meet the unique challenges and safety requirements
of the mining industry.

IS Rating: IS 5553 is one of the standards

applicable to mining transformers.

3.3.11 PHASE SHIFTING TRANSFORMER:

Phase Shifting Transformer (PST) is a specialized

type of power transformer used in electrical power
systems to control and adjust the phase angle of the
voltage between its primary and secondary
windings. This adjustment of the phase angle is
achieved by varying the turns ratio between the
primary and secondary windings. Phase shifting
transformers play a crucial role in power systems for
various applications, including load balancing,
power flow control, and voltage regulation.

IS Rating: Phase shifting transformers may adhere

to IS 6600 specifications.

3.3.12 HIGH VOLTAGE TESTING TRANSFORMER:

High Voltage Testing Transformer, often referred to as a high-

voltage transformer or HV test transformer, is a specialized electrical
device designed to generate high-voltage, high-frequency alternating
current (AC) or direct current (DC) for conducting various tests on
electrical equipment, insulation materials, and components.

IS Rating: IS 4722 specifications apply to high voltage testing

transformers.

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3.3.13 GROUNDING TRANSFORMER:

Grounding transformers, also known as an earthing

transformer, plays a critical role in establishing a safe
and reliable electrical distribution system. Its primary
function is to provide a path for fault current to safely
dissipate into the earth in the event of a ground fault or
short circuit in the electrical system.

IS Rating: Grounding transformers may adhere to IS

3156 specifications.

3.3.14 DRY TYPE TRANSFORMER

A dry-type transformer is a type of electrical

transformer that does not use liquid cooling or
insulating substances like oil. Instead, it relies on air or
other solid insulation materials to cool and insulate its
windings. Dry-type transformers are commonly used in
various applications, including buildings, industrial
facilities, and outdoor installations, where the use of oil-
filled transformers may not be practical or safe due to
environmental concerns, fire hazards, or maintenance
considerations.

IS Rating: Dry type transformers may adhere to IS 2026 specifications

3.3.15 CONVERTER TRANSFORMER:

Converter transformer is a specialized type of

transformer designed for use in high-voltage direct
current (HVDC) systems. These transformers are
essential components in HVDC transmission systems,
which are used to transmit electrical power over long
distances with reduced energy losses compared to
traditional alternating current (AC) transmission.

IS Rating: IS 6600 may apply to certain types of

converter transformers.

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3.4 PARTS OF TRANSFORMER

• CORE • BREATHER

• WINDING • RADIATORS AND FANS

• CORE INSULATION • EXPLOSION VENT

• TANK • BUCHHOLZ RELAY

• TERMINALS AND BUSHINGS • TAP CHANGER

• TRANSFORMER OIL • TEMPERATURE INDICATOR

• CONSERVATOR

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3.4.1 CORE

The core, made of stacked high-

grade grain-oriented steel sheets
separated by insulating material,
provides a low-reluctance path for
electromagnetic flux, supporting
both primary and secondary
windings. To minimize hysteresis
and eddy currents, the core's steel
has a carbon content below 0.1%
and can be alloyed with silicon. In a
typical three-phase transformer core, limbs carry both primary and secondary windings and are
magnetically coupled by yokes. Core constructions include core type and shell type.

3.4.2 WINDING

A transformer consists of primary and secondary

windings with different voltage ratings. The primary
winding, rated for higher voltage, is called the High
Voltage (HV) winding, while the other is the Low
Voltage (LV) winding. The HV winding has thinner
conductors and surrounds the LV winding, which is
positioned closer to the core. In shell-type
transformers, windings are divided into coils, while
core-type transformers offer options like Multi-layer,
Helical, Disc, or Foil windings, chosen based on turns
and current capacity requirements.

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3.4.3 CORE INSULATION

Insulation is the most important part of transformers.

Insulation failures can cause the most severe damage
to transformers. Insulation is required between the
windings and the core, between windings, between
each turn of the winding, and between all current-
carrying parts and the tank. The insulators should
have high dielectric strength, good mechanical
properties, and high-temperature withstand ability.
Synthetic materials, paper, cotton, etc are used as
insulation in transformers.

3.4.4 TANK

Tank bodies are made by fabricating rolled steel plates

into containers. They are provided with lifting hooks
and cooling tubes. In order to reduce weight and stray
losses, aluminium sheets are also used instead of steel
plates. However, aluminium tanks are costlier than
steel ones.

The main purpose is to Protects the core and the

windings from the external environment. and Serves
as a container for oil and support for all other
transformer accessories.

3.4.5 TERMINAL AND BUSHINGS

For connecting incoming and outgoing cables,

terminals are present in transformers. They are
mounted upon the bushings and connected to the
windings’ ends.

Bushings are insulators that form a barrier between the

terminals and the tank. They are mounted over the
transformer tanks. They are a safe passage for the
conductors connecting terminals to the windings. They
are made from porcelain or epoxy resins.

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3.4.6 TRANSFORMER OIL

In all oil-immersed transformers, transformer oil

provides added insulation between the
conducting parts, better heat dissipation, and
fault detection features. Hydro-carbon mineral
oil is used as transformer oil. It is composed of
aromatics, paraffin, naphthene’s, and olefins.
Transformer oil has a flashpoint of 310 degrees
Celsius, a relative permeability of 2.7, and a
density of 0.96 kg/cm3.Withstand capacitance of
65kV.

3.4.7 CONSERVATORS

The oil conservator is moved on top of the

transformers and is located well above the tank
and bushings. Normally a rubber bladder is
present in some oil conservators. The transformer
oil expands and contracts with an increase and
decrease in temperature. The oil conservator
provides adequate space for oil expansion. It is
connected to the main tank through a pipe. A level
indicator is fitted to the conservator to indicate the
oil level inside.

3.4.8 BREATHER

Breather is present in all oil-immersed

transformers that have a conservator tank. It is
necessary to keep the oil-free from moisture. As
the temperature variations cause the transformer
oil to expand and contact, air flows in and out of
the conservator tank. This air should be free
from moisture. Breather serves this purpose.

A breather is attached to the end of the air pipe

such that the air enters and exits the conservator
through it. The silica gel present in the breathers removes moisture from the air and delivers
moisture-free air to the conservator.

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3.4.9 RADIATORS AND FANS

The power lost in the transformer is

dissipated in the form of heat. Dry
transformers are mostly natural air-cooled.
But when it comes to oil-immersed
transformers, a variety of cooling methods
are followed. Depending on the kVA rating,
power losses, and level of cooling
requirements, radiators and cooling fans are
mounted on the transformer tank.

Parts of a transformer: Radiators and cooling

fans

The heat generated in the core and winding is passed to the surrounding transformer oil. This heat
is dissipated at the radiator. In larger transformers forced cooling is achieved with the help of
cooling fans fitted to the radiators.

3.4.10 EXPLOSION VENT

An explosion vent acts as an emergency exit

for oil and air gases inside a transformer. It is
a metallic pipe with a diaphragm at one end,
held slightly above the conservator tank.
Faults occurring under oil elevate the pressure
inside the tank to dangerous levels. Under
such circumstances, the diaphragm ruptures at
a relatively low pressure to release the forces
from within the transformer to the
atmosphere.

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3.4.11 TAP CHANGERS

Tap changers are used to adjust the secondary voltage of

transformers. They are designed to change the turn ratio of the
transformer as required. There are two types of tap changers:
On-load tap changers and Off-load tap changers.

Off-load tap changers are designed to operate only when the

transformer is not supplying any loads whereas on-load tap
changers are capable of operating without interrupting the
current flow to the load. Automatic tap changers are also
available.

3.4.12 BUCHHOLZ RELAY

Buchholz relay is one of the most important parts of oil-

immersed transformers rated over 500kVA. It is an oil and gas
actuated relay that is used to sense faults occurring in the parts
immersed in the oil.

Short circuits occurring under the transformer oil generate

enough heat to decompose the oil into hydrogen, carbon
monoxide, methane, etc. These gases gradually move toward the
conservator tank through the connecting pipe. Buchholz relay,
which is mounted on the pipe connecting the conservator tank
and the main tank, senses these gases and activates the trip and
alarm circuits. The trip circuit opens the circuit breaker supplying current to the primary winding
and interrupts the current flow.

3.4.13 TEMPERATURE INDICATOR

Temperature indicators in transformers

monitor key components for safety. They
include dial and digital gauges, RTDs, and
thermocouples, typically placed in windings,
oil, and sometimes top oil. They can trigger
alarms and are vital for preventing
overheating, ensuring efficient operation, and
predicting maintenance needs.

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3.5 MANUFACTURING PROCESS OF TRANSFORMER

• WINDING CONSTRUCTION • TANKING & FINAL FITTING

• CORE ASSEMBLY • FITTINGS & ACCESSORIES

• CORE & WINDING ASSEMBLY • PAINTING

• TAPPING &TAP CHANGER • OIL FILLING & FILTRATION

• DRYING PROCESS • TESTING

3.5.1 WINDING CONSTRUCTION:

The winding process involves creating coils of insulated copper or aluminum wire. These coils
form the primary (high-voltage) and secondary (low-voltage) windings of the transformer.
Windings mainly depend on the input-output supply otherwise on the range of voltage. There are
two types of winding construction Core type Winding and shell type winding.

The number of turns and wire size are precisely calculated to achieve the desired voltage
transformation ratio. The turns ratio of a transformer is defined as the number of turns on its
secondary divided by the number of turns on its primary.

The turns ratio is expressed with two numbers, like 2:1 or 2 to 1. The first number represents the
primary's relative number of turns and the second number represents the secondary's relative
number of turns. The turns ratio of a transformer is calculated by formula:
Where, NP = number of turns in the primary winding,
NS = number of turns in the secondary winding
Example: What is the turns ratio of a transformer with 500 turns in the primary winding and 1000
turns in the secondary winding?

3.5.2 CORE ASSEMBLY:

The core is usually made of laminated steel sheets to minimize eddy current losses. These sheets
are stacked and tightly bound together using clamps or bolts.

The core's shape and size are designed to meet the transformer's specific requirements.

There are two types of Core Assemble Core type core and Shell type core

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3.5.3 CORE & WINDING ASSEMBLY:

The windings are carefully placed around the core. The primary and secondary windings are
positioned with insulating material in between to prevent electrical contact.

This assembly is crucial for efficient energy transfer between the windings.

3.5.4 TAPPING & TAP CHANGER:

Some transformers have multiple taps on their windings, allowing

adjustment of the output voltage to compensate for variations in
the input voltage.

A tap changer is a mechanism that enables these adjustments and

ensures the desired output voltage is maintained.

2.5.6 DRYING PROCESS:

After assembly, the transformer undergoes a drying process to remove any moisture that may have
entered during construction.

Typically, the transformer is placed in an oven or subjected to vacuum and heat to eliminate
moisture.

2.5.7 TANKING & FINAL FITTING:

The dried transformer is then placed inside a tank filled with oil or a suitable insulating medium.

The tank provides mechanical protection, insulation, and cooling for the transformer.

Final fittings, such as bushings and cable terminals, are installed on the tank.

2.5.8 FITTINGS & ACCESSORIES:

Various accessories like conservators, breather devices, and pressure relief valves are added to the
transformer to enhance its performance and safety.

2.5.9 PAINTING:

The exterior of the tank is painted to protect it from environmental factors and corrosion.

2.5.10 OIL FILLING & FILTRATION:

Transformer oil is filled into the tank to immerse the core and windings. The oil serves as both an
insulator and a coolant. This oil is often filtered to remove impurities before filling and again
drying process through oven or through subjected vacuum to remove moisture from oil.

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2.5.11 TESTING:

Transformers undergo of tests to ensure their performance and safety. These tests include:

Dielectric Strength Test: To check the insulation's ability to withstand high voltage.
Resistance Measurement: To verify the windings' integrity.
Oil BVD test: To ensure the oil withstand capacity.
Transformer Oil and Winding temperature test: To check the temperature rising limit.
Load and No-load Tests: To assess efficiency and voltage regulation.
Partial Discharge Test: To detect potential insulation problems.
Short-Circuit Test: To evaluate the transformer's ability to handle short-circuit conditions.
Impulse Voltage Test: To assess the transformer's ability to withstand lightning strikes and
transient voltage surges.

3.6 TESTING OF TRANSFORMER

3.6.1 DIELECTRIC STRENGTH TEST:

The Dielectric Strength Test, also known as the "Hi-Pot Test," is crucial in assessing a
transformer's insulation. It checks if the transformer can handle high voltage without issues. Here's
a brief overview of how it's done:

Test Procedure:
• Gradually raise the test voltage, often 1.5 to 2 times the rated voltage.
• Apply the test voltage across the transformer windings for a specified duration, usually around
one minute.
Observation:
• Ensure the transformer's insulation doesn't break down during the test.
• Any sudden current surge or electrical discharge signals a failure.
• Success means the insulation endures the voltage for the set duration without issues.
Test Evaluation:
• After the test, inspect the transformer for damage or deterioration.
• Measure insulation resistance to verify it meets acceptable limits.
Record Keeping:
• Keep detailed records of test parameters, such as voltage, duration, and observations, for
documentation and quality control.

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3.6.2 RESISTANCE MEASUREMENT:

Resistance measurement tests are conducted on transformers to assess the integrity of the windings
and connections.

Test Procedure:
The transformer is de-energized, a known current flow through the winding, and the voltmeter
measures the drop. Ohm's law calculates the resistance (R).
Comparing Results:
Measured resistance is compared to expected values. Deviations may signal issues with windings or
connections.
Temperature Correction:
Copper or aluminum winding resistance depends on temperature. Measurements are often corrected
to a reference temperature (e.g., 20°C).
Interpreting Results:
If measured resistance aligns with specs, windings and connections are likely fine. Deviations may
indicate problems like loose connections or overheating, needing further inspection and maintenance.

3.6.3 OIL BVD TEST:

Oil Breakdown Voltage (BDV) test is an essential diagnostic test conducted on the insulating oil
used in transformers. This test is performed to assess the dielectric strength or insulating properties
of the transformer oil.

Test Procedure
The test cell is filled with the prepared oil sample, and the two electrodes are immersed in the oil.
A voltage is applied across the electrodes, gradually increasing in steps until a breakdown
occurs.
The breakdown voltage is the voltage level at which a visible electrical discharge or arc occurs in the
oil. This indicates the breakdown of the oil's dielectric strength.
Recording Results
The breakdown voltage is recorded and compared to the specified standards or requirements for the
transformer's insulating oil.
The test results are typically reported in kV (kilovolts).

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3.6.4 TRANSFORMER OIL AND WINDING TEMPERATURE TEST:

TRANSFORMER OIL TEST: The transformer oil, also known as insulating oil, plays a critical role
in cooling and insulating the transformer. The oil test helps determine the oil's quality and
condition, ensuring it can effectively perform its functions.

Acidity Test:
This test assesses the acidity or pH level of the oil. Elevated acidity can indicate the presence of
contaminants or degradation of the oil.
Water Content Test:
Transformers should have minimal moisture content in the oil. Excess moisture can lead to reduced
dielectric strength and insulation breakdown.
Dissolved Gas Analysis (DGA):
DGA measures the concentration of dissolved gases in the oil. Certain gases, such as methane,
ethylene, and hydrogen, can indicate potential problems within the transformer, like overheating or
partial discharges.
Flash Point Test:
This test determines the temperature at which the oil vapor can ignite in the presence of an open flame.
It's a safety measure to assess the risk of fire.

WINDING TEMPERATURE TEST: Monitoring the temperature of the windings is crucial to ensure
the transformer operates within safe temperature limits. Excessive heat can lead to insulation
breakdown and reduced transformer life.

Temperature Sensors:
Temperature sensors (thermocouples or resistance temperature detectors) are placed on or inside the
windings to continuously monitor temperature.
Temperature Rise Test:
During this test, the transformer is subjected to full-load conditions, and temperature sensors record the
temperature rise in the windings.
Thermal Imaging:
Infrared thermography can be used to identify hotspots and temperature irregularities in the
transformer.

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3.6.5 LOAD AND NO-LOAD TESTS:

Load and no-load tests are essential tests performed on transformers to evaluate their performance
and characteristics. These tests help determine the efficiency, voltage regulation, and other
important parameters of the transformer.

NO-LOAD TEST (OPEN-CIRCUIT TEST): The primary purpose of the no-load test is to measure
the core loss and magnetizing current of the transformer under no-load conditions. It helps
determine the iron or core losses and the exciting current required to maintain magnetization.

Procedure:
The secondary winding is left open, meaning there is no load connected to it.
A reduced voltage is applied to the primary winding (usually at rated frequency) to simulate the normal
operating conditions.
The primary current, primary voltage, and power factor are measured.
Data Obtained:
Core loss or iron loss (P_no-load) in watts.
Magnetizing current (I_magnetizing).
No-load current (I_no-load).
No-load power factor (cosφ_no-load).
Analysis:
The core loss is determined from the power dissipated in the core (P_no-load).
The magnetizing current and power factor provide information about the magnetization characteristics
of the transformer.
The no-load current and power factor indicate the excitation requirements of the transformer.

LOAD TEST (SHORT-CIRCUIT TEST): The load test is performed to evaluate the copper or
winding losses and the impedance characteristics of the transformer under load conditions. It helps
determine the transformer's efficiency and voltage regulation at various load levels.

Procedure:
The secondary winding is short-circuited (i.e., a low-voltage, high-current circuit is connected to it).
A variable voltage is applied to the primary winding to vary the load current.
Measurements of primary current, primary voltage, and power factor are taken at different load levels.
Data Obtained:
Copper or winding losses (P_load) in watts.
Load current (I_load) and load power factor (cosφ_load) at various load levels.
Impedance voltage drop (V_drop) at various load levels.
Analysis:
The copper losses (P_load) are determined by subtracting the core loss from the total power loss
measured during the test.
Load current and power factor data help calculate the efficiency and voltage regulation of the
transformer at different loads.
Impedance voltage drop data provide information about the transformer's impedance characteristics.

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3.6.6 PARTIAL DISCHARGE TEST:

The Partial Discharge Test, often referred to as the PD Test, is a critical test performed on
transformers and other high-voltage electrical equipment to assess the insulation's quality and
integrity.

Test Procedure:
A test voltage, typically a high-frequency AC voltage or a repetitive impulse voltage, is applied to the
transformer's insulation.
The test voltage is gradually increased until partial discharges occur within the insulation.
During partial discharges, small amounts of electrical energy are released as discharges or sparks at
localized points of insulation breakdown.
The sensors detect these partial discharges.
Data Collection:
The test equipment records data related to the magnitude, location, and frequency of the partial
discharges.
This data is analyzed to assess the severity and nature of the insulation defects.
Analysis:
Skilled technicians or engineers interpret the test results. They analyze the data to determine the
severity of the partial discharges and assess the overall condition of the transformer's insulation.
It's important to differentiate between acceptable partial discharges that may occur within the
transformer's design limits and potentially harmful discharges that indicate insulation defects.

3.6.7 SHORT-CIRCUIT TEST:

The Short-Circuit Test, also known as the Impedance or Copper Loss Test, is a critical test
conducted on transformers during their manufacturing and commissioning stages. This test is
performed to evaluate the transformer's ability to withstand short-circuit conditions and to
determine its impedance or copper losses under such circumstances.

Short-Circuit:
The low-voltage winding is short-circuited.
The high current flows through the short-circuited winding, creating a magnetic field within the
transformer's core.
Measurement:
The primary current, secondary current (if applicable), and primary voltage are carefully measured
during the test.
The primary and secondary losses are calculated based on the measured values.
Duration:
The test is typically conducted for a short duration, often just a few minutes, to avoid excessive heating
and potential damage to the transformer.
Results and Analysis:
The results of the Short-Circuit Test provide valuable information about the transformer's impedance,
copper losses, and its ability to handle short-circuit currents.
By comparing the losses under short-circuit conditions to the losses under normal operating conditions
(as determined by the No-load and Load Tests), engineers can evaluate the overall efficiency and
performance of the transformer.

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3.6.8 IMPULSE VOLTAGE TEST:

The Impulse Voltage Test is an essential test conducted on transformers to assess their ability to
withstand transient voltage surges, such as lightning strikes and switching surges. This test is
performed to ensure the transformer's insulation system can endure these high-voltage impulses
without suffering damage.

Test Procedure:
The transformer's terminals are connected to the impulse generator.
A standardized impulse voltage waveform, such as the standard lightning impulse (1.2/50 μs
waveform) or chopped wave, is applied to the transformer's windings.
Observation and Measurement:
During the test, the response of the transformer's insulation to the impulse voltage is closely monitored.
Instruments record parameters such as the voltage across the windings, the current through the
windings, and any partial discharges that may occur.
Evaluation:
The test results are evaluated to determine whether the transformer's insulation system has withstood
the applied impulse voltage without breakdown or excessive damage.
If the insulation withstands the impulse voltage within specified limits, the transformer is considered to
have passed the test.
Pass/Fail Criteria:
The pass/fail criteria for the Impulse Voltage Test are typically defined by international or industry
standards (e.g., IEC, IEEE). These criteria specify the acceptable voltage withstand levels and the
maximum allowable partial discharges.

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 3.7 VECTOR GROUP OF TRANSFORMERS

ION

Three phase transformer consists of three sets of primary winding, one for each phase, and three
sets of secondary windings wound on the same iron core. Separate single-phase transformers can
be used and externally interconnected to yield the same results as a 3-phase unit.

The primary windings are connected in one of several ways. The two most common configurations
are the delta, in which the end of one winding is connected to the non-polarity end of the next, and
the star, in which all three non-polarities (or polarity) ends are connected together. The secondary
windings are connected similarly. This means that a 3-phase transformer can have its primary and
secondary windings connected the same (delta-delta or star-star), or differently (delta-star or star-
delta).

But when the primary and secondary windings are connected differently, the secondary voltage
waveforms will differ from the corresponding primary voltage waveforms by 30 electrical degrees.
This is called a 30-degree phase shift. When two transformers are connected in parallel, their phase
shifts must be identical; if not, a short circuit will occur when the transformers are energized.”

Why is the vector group important to specify?

As different combinations of winding connections will result in different phase angles between the
voltages on the windings, transformers connected in parallel must have the same vector group
because the mismatching of phase angles will result in circulating current and other system
disturbances.

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 SIX WAYS TO WIRE STAR WINDING SIX WAYS TO WIRE STAR WINDING

POLIRITY

Page | 31
3.7.2 POLARITY

An AC voltage applied to a coil will

induce a voltage in a second coil
where the two are linked by a
magnetic path. The phase
relationship of the two voltages
depends upon which way round the
coils are connected. The voltages
will either be in-phase or displaced
by 180 deg.

When 3 coils are used in a 3-phase transformer winding a number of options exist. The coil
voltages can be in phase or displaced as above with the coils connected in star or delta and, in the
case of a star winding, have the star point (neutral) brought out to an external terminal or not.

3.7.3 VECTOR GROUP OF TRANSFORMERS

The three phase transformer windings can be connected several ways. Based on the windings’
connection, the vector group of the transformer is determined.

The Determination of vector group of transformers is very important before connecting two or
more transformers in parallel. If two transformers of different vector groups are connected in
parallel then phase difference exist between the secondary of the transformers and large
circulating current flows between the two transformers which is very detrimental.

3.7.4 PHASE DISPLACEMENT BETWEEN HV & LV WINDINGS

The vector for the high voltage winding is taken as the reference vector. Displacement of the
vectors of other windings from the reference vector, with anticlockwise rotation, is represented
by the use of clock hour figure.

IS 2026 gives 26 sets of connections star-star, star-delta, and star zigzag, delta-delta, delta star,
delta-zigzag, zigzag star, zigzag-delta. Displacement of the low voltage winding vector varies
from zero to -330° in steps of -30°, depending on the method of connections.

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3.8 MAINTENANCE OF TRANSFORMER:

• Visual Inspection: Regular visual inspections to check for oil leaks, loose connections,
damaged bushings, and signs of overheating or corrosion.
• Oil Analysis: Periodic sampling and analysis of the transformer oil to detect contamination,
aging, or moisture ingress.
• Temperature Monitoring: Monitoring the operating temperature of the transformer's
windings and oil to detect abnormal heating.
• Dissolved Gas Analysis (DGA): Measuring and analyzing gases dissolved in the
transformer oil to identify potential internal issues, such as overheating or arcing.
• Load Monitoring: Continuously monitoring the transformer's load to ensure it operates
within its rated capacity.
• Insulation Resistance Testing: Conducting insulation resistance tests to assess the condition
of the insulation materials.

3.9 PROTECTION OF TRANSFORMER:

• Overcurrent Protection: Devices like relays and circuit breakers are used to trip the
transformer offline in case of excessive current.
• Differential Protection: Differential relays compare the current entering and leaving the
transformer windings to detect internal faults.
• Buchholz Relay: Installed in oil-filled transformers to detect and respond to incipient faults
and gas accumulation within the transformer.
• Pressure Relief Devices: Pressure relief valves prevent excessive pressure buildup in the
transformer tank during fault conditions.
• Temperature Monitoring: Temperature sensors and relays are used to trigger alarms or trip
the transformer if the temperature exceeds safe limits.

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3.10 FAILURE & CAUSES OF TRANSFORMER FAILURE:

• Overloading: Operating the transformer beyond its rated capacity, leading to overheating
and insulation breakdown.
• Short Circuits: Sudden electrical faults can cause high currents and mechanical stresses,
damaging the windings and core.
• Aging: Transformers degrade over time due to factors like insulation breakdown, oil
degradation, and core aging.
• Moisture Ingress: Moisture entering the transformer can lead to insulation breakdown and
corrosion.
• Insulation breakdown: Aging or excessive electrical stresses can cause insulation failure,
leading to short circuits.
• Overheating: Overloading, poor cooling, or poor ventilation can cause the transformer to
overheat.
• Contamination: Contaminated oil or solid particles can deteriorate insulation and lead to
failures.
• Mechanical Stress: Physical damage or excessive vibrations can damage windings and the
core.
• Lightning Strikes and Surges: Lightning strikes and voltage surges can cause insulation
breakdown and winding damage.

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4. KEY LEARNINGS

Throughout the internship at Kirloskar, several key learnings emerged, contributing to a deeper
understanding of transformer manufacturing and professional development in the field of
electrical engineering. These learnings encompassed technical insights, practical skills, and
broader lessons that will undoubtedly shape my future endeavors in the industry.

1. Technical Proficiency

One of the foremost learnings was the development of technical proficiency in transformer
design, fabrication, and testing. Through hands-on experience and mentorship, I gained a
comprehensive understanding of core concepts such as voltage regulation, impedance matching,
and insulation coordination. Moreover, exposure to advanced software tools for design
simulation and analysis augmented my technical toolkit, enabling me to approach engineering
challenges with confidence and competence.

2. Quality Assurance

Quality assurance emerged as a paramount consideration in transformer manufacturing,

underscoring the importance of precision and adherence to standards. I learned that every stage
of production, from material selection to final testing, must undergo rigorous scrutiny to ensure
optimal performance and reliability. Implementing quality control measures and protocols not
only mitigates operational risks but also enhances customer satisfaction and brand reputation—a
lesson that will resonate in my future engineering endeavors.

3. Collaboration and Communication

Effective collaboration and communication were indispensable for success in the internship.
Working alongside multidisciplinary teams, I realized the significance of clear and concise
communication in fostering synergy and alignment towards common goals. Whether liaising
with design engineers, production supervisors, or quality assurance specialists, I honed
interpersonal skills essential for navigating dynamic work environments and fostering a culture
of teamwork and collaboration.

4. Problem-Solving Skills

The internship presented numerous challenges and obstacles, ranging from technical
complexities to logistical constraints. However, these challenges served as opportunities for
growth and learning. I learned to approach problems systematically, leveraging analytical
thinking and creativity to identify root causes and implement effective solutions. Moreover,
exposure to real-world scenarios cultivated resilience and adaptability, traits crucial for thriving
in the fast-paced and dynamic landscape of engineering.

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5. Professional Ethics and Integrity

Ethical conduct and integrity formed the cornerstone of my experience at Kirloskar. I learned
that upholding ethical standards and principles is non-negotiable in the engineering profession,
encompassing aspects such as transparency, accountability, and respect for intellectual property.
By adhering to ethical guidelines and industry best practices, I gained a deeper appreciation for
the ethical dimensions of engineering practice and the broader societal implications of
technological innovation.

In essence, the internship at Kirloskar was a transformative journey that fostered technical
proficiency, interpersonal skills, and ethical awareness essential for success in the field of
electrical engineering. The key learnings garnered from this experience will undoubtedly serve as
guiding principles as I navigate future endeavors, contributing to personal growth, professional
excellence, and societal impact.

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5. CONCLUSION

The culmination of the internship at Kirloskar marks not only the end of a transformative journey
but also the beginning of a new chapter in my engineering career. Over the course of this
immersive experience, I have gained invaluable insights, honed essential skills, and forged
meaningful connections that will undoubtedly shape my future trajectory in the field of electrical
engineering.

Reflecting on the journey, I am deeply grateful for the opportunity to delve into the realm of
transformer manufacturing, a cornerstone of the electrical engineering industry. From
understanding the nuances of transformer design to witnessing the intricacies of production
processes firsthand, each aspect of the internship has contributed to my professional growth and
development.

The key learnings garnered—from technical proficiency to collaboration and problem-solving

skills—have equipped me with a robust foundation to tackle complex engineering challenges
with confidence and competence. Moreover, the emphasis on quality assurance, ethical conduct,
and professionalism has instilled a sense of responsibility and integrity that will guide my actions
and decisions in future endeavors.

As I bid farewell to Kirloskar and embark on the next phase of my engineering journey, I carry
with me a profound appreciation for the opportunities, mentorship, and experiences that have
shaped my growth during the internship. I am eager to leverage these learnings and insights as I
contribute to the advancement of the engineering profession, driving innovation, sustainability,
and societal impact.

In closing, I extend my heartfelt gratitude to Kirloskar for the invaluable learning experience, to
my mentors and colleagues for their guidance and support, and to the engineering community at
large for inspiring me to pursue excellence and make a positive difference in the world. With
enthusiasm and determination, I look forward to embracing the challenges and opportunities that
lie ahead, confident in my ability to create meaningful impact and leave a lasting legacy in the
field of electrical engineering.

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