Power plant engineering works

Manufactures & Repairs of transformers

 AN INDUSTRIAL TRAINING REPORT
On

Power plant engineering works

A detailed report on submitted in the partial fulfilments of the requirement under

training for the award of

DIPLOMA IN ELECTRICAL AND ELECTRONICS ENGINEERING

Under the esteemed guidance

of

Sri A.Ramesh (M-Tech)

Head of the section

Sri B.SESHA SAI (M-TECH)

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING GOVERNMENT

POLYTECHNIC PENDURTHI

VISAKHAPATNAM, A.P
[2022-2025]
DIPLOMA IN ELECTRICAL AND ELECTRONICS ENGINEERING

GOVERNMENT POLYTECHINC PENDURTHI

 CERTIFICATE

This is to certify that Ms. TUTA SAI bearing the Pin: 22637- EE-
057 is a Bonafide student of Government Polytechnic Pendurthi,
has Completed Industrial Training at Power plant engineering,
Visakhapatnam and has submitted the training report to the
institute in Partial Fulfilment of the requirement for the award of
diploma in Electrical and Electronic Engineering during the
period from May 2024 - November 2024.

During the above-mentioned period, her conduct & performance

were found to be .

B.Sesha Sai ,M.Tech Dr.N.CHANDRA SHEKHAR, M.Tech.,Ph.D.

Head of EEE Department Principal
Government Polytechnic Government Polytechnic
Pendurthi, Visakhapatnam Pendurthi, Visakhapatnam
 Table of Contents
Page Nos.

A. Acknowledgement 1
B. Abstract 3
Chapter 1: TRANSFORMERS
1.1 Introduction to Transformers 4
1.2 Construction of Transformers 5
1.3 Working Principle of Transformers 10
1.4 Types of Transformers 12
Chapter 2: TESTS ON TRANSFORMERS
2.1 Introduction 19
2.2 Types of Tests 20
Chapter 3: CIRCUIT BREAKERS
3.1 Introduction 33
3.2 Types of Circuit Breakers 34
Chapter 4: INSPECTION OF COILS
4.1 Introduction 35
4.2 1st Inspection 36
4.3 2nd Inspection 36
4.4 Photos collected from company 37
Chapter 5: SINGLE PHASE TRANSFORMERS
5.1 Introduction 38
5.2 Explanation 39
Chapter 6: THREE PHASE TRANSFORMERS
6.1 Introduction 41
6.2 Explanation 42
 Page Nos.

Chapter 7: MACHINES IN THE COMPANY

7.1 Introduction 44
7.2 Explanation 44
7.3 Conclusion 51
Chapter 8: PROCEDURE OF REPAIRING OF TRANSFORMERS
8.1 Introduction 52
8.2 Steps involved in Transformer Repairing 52
8.3 Common Transformer repair Scenarios 55
8.4 Advantages of Transformer repair 55
8.5 Conclusion 55
CONCLUSION 56
 ACKNOWLEDGEMENT

It is my great fortune that I have got opportunity to carry out this project work under the
supervision of, Sri A.Ramesh, in power plant engineering works,Autonagar,

‘E’ Block, Visakhapatnam-44

We wish to convey my gratitude to our respected principal Dr. N. Chandra Shekhar,

MTech, PhD, our HOD Sri, B.Sesha sai, MTech, and staff incharge for our industry
Sri, B.Sesha sai who have been an anchor throughout our training period, we express
our sincere thanks and deepest sense of gratitude to their constant support, unparalleled
guidance, and limitless encouragement.

We would also like to convey my gratitude to A.Ramesh garu and all the members in
the Power plant engineering, who immensely helped us to acquire enough knowledge
during our Industrial training at Power plant engineering works and all the faculty
members and staffs of the department of Electrical Engineering, Government
Polytechnic PENDURTHI for their wholehearted cooperation to make this work turn into
reality.
 ABSTRACT

This document provides an in-depth exploration of POWER PLANT

ENGINEERING, covering their essential components, types, and operational
principles. A
transformer is a critical electrical device used to transfer electrical energy between
circuits through electromagnetic induction. The study includes a breakdown of the
parts of a transformer, such as the core, windings, and bushings, and provides
insights into different types of transformers based on design, usage, and voltage
levels.
A detailed section on bushings discusses their role in insulation and electrical
connections, followed by an overview of types of bushings commonly employed
for various applications. The significance of transformer reliability is emphasized
through a description of testing procedures for performance evaluation and fault
detection, as well as guidelines for inspection routines to ensure operational
safety. The discussion on windings explains their construction and role in achieving
efficient voltage regulation.
Additionally, the concept of amorphous jobs is introduced, focusing on the
use of amorphous metal cores to enhance efficiency by reducing core losses. The
final section outlines the procedure for complete repair of a transformer, offering
a step-by-step guide on disassembly, fault diagnosis, repair, reassembly, and post-
repair testing to restore the transformer to optimal working condition.
This comprehensive overview of POWER PLANT ENGINEERING serves as a
valuable reference for professionals in the electrical engineering field, ensuring a
thoroughunderstanding of transformer technology, maintenance, and repair
practices.

3
 CHAPTER – 1
TRANSFORMERS

1.1 Introduction to transformers

The transformer, in a simple way, can be described as a device that steps up
or steps down voltage. In a step-up transformer, the output voltage is increased, and
in a step-down transformer, the output voltage is decreased. The step-up
transformer will decrease the output current, and the step-down transformer will
increase the output current to keep the input and output power of the system equal.
The transformer is basically a voltage control device that is used widely in the
distribution and transmission of alternating current power. The idea of a transformer
was first discussed by Michael Faraday in the year 1831 and was carried forward by
many other prominent science scholars. However, the general purpose of using
transformers was to maintain a balance between the electricity that was generated
at very high voltages and consumption which was done at very low voltages.

4
 1.2 Construction of Transformer
The construction of transformer is very simple for the small-sized
transformer. It consists of a transformer core, primary and secondary windings.
For a high range of power transformers, the core and windings are placed in a
transformer tank with additional accessories.
The main components involved in the construction of transformer are as
follows

 Transformer core
 Primary and Secondary windings
 Insulating Oil
 Transformer tank
 Oil conservator
 Breather
 Cooling tubes
 Buchholz Relay
 Explosion Vent

5
  Transformer Core:
The transformer core is mainly used for two purposes: Provide mechanical
support for the entire transformer and provide a path for the flow of magnetic flux
 The core is built up of soft iron or silicon steel laminations to provide a low
reluctance path to the magnetic flux. The steel used should have high silicon
content and be treated with heat to have better permeability and low hysteresis
loss.
 The laminations are insulated from each other by a coat of varnish or by an oxide
layer. These laminations reduce the eddy current loss. The thickness of the
laminations varies from 0.35 mm to 0.5 mm.
 The laminations in the form of strips called stampings are joined together and
pivoted to avoid any air gaps between the core. Various types of stampings like
‘E’ shaped, ‘I’ shaped, ‘L’ shaped and ‘U’ shaped stampings are used for the
construction of transformer.
 Windings:
 The transformer has two windings: primary winding and secondary winding. The
primary winding is connected to the power supply and the secondary winding is
connected to the load.
 The winding connected to the high voltage circuit is called high voltage (HV)
winding. The winding connected to the low voltage circuit is called low voltage
(LV) winding.

6
 Transformer tank and insulating oil
 The transformer core and winding arrangement are immersed in a tank
containing insulating oil. The tank gives protection to the core and
windings. Cooling tubes are welded with the tank for cooling purposes.
 The insulating oil act as an insulation medium for core and windings. It
is also used for absorbing the heat in the windings and core.

Transformer Main Tank

 Oil conservator:

Conservator Tank

7
  The transformer tank is connected through a pipe to a small tank called
the conservator. The Conservator is designed to act as a reservoir for
the transformer oil.
 An increase in temperature causes the oil in the transformer to expand.
The conservator provides space for this expansion of the oil. The main
function of the oil conservator is to keep the transformer tank
completely filled with oil at all conditions.
 Breather
 Breather is a part of a large-sized transformer. During the change in
temperature inside the tank, the oil expands and contracts.
 For example, when the temperature goes down, it will make the oil to
contract. So, atmospheric air gets absorbed inside a transformer tank.
This process is similar to breathing in human beings and so-called as a
breather.
 Breather consists of silica gel, which prevents any atmospheric moisture
from entering the tank from the outside world. All the moisture gets
absorbed by the silica gel.

Silica gel Breather

8
 Cooling Tubes
 The heat is produced in the windings and core due to copper loss in the
conductors, hysteresis and eddy current loss in the transformer core.
This heat has to be dissipated to operate the transformer efficiently.
 The cooling tubes are used to remove the heat from the transformer
oil and tank. Through this cooling tube, coolants in the form of oil or
air are passed inside a transformer. The cooling method may be natural
or forced cooling, which depends on the size of a transformer.

Cooling Tubes

 Buchholz Relay
 Buchholz Relay is an important part of the construction of transformer.
Buchholz Relay is a device used to protect the transformer from faults
occurring inside the tank. It is a gas and oil actuated relay. The relay is
placed between the transformer tank and the conservator.

Buchholz Relay

9
  Whenever a fault like a failure of insulation or damage to the core takes
place, it results in the production of excess heat. This heat will
decompose the oil and produce bubbles. These bubbles flow in the
upward direction towards the conservator and get collected in the relay.
The production of bubbles depends on the intensity of faults.
 The bubble thus produced inside a transformer tank will activate the
relay and give an alarm signal, indicating that there was a fault inside
the tank. This will enable the operating person to disconnect the supply
to the transformer.
 Explosion vent
 The transformer has an explosion vent to prevent any damage to the
transformer tank caused by the excessive pressure generated inside
the transformer.
 If an explosion occurs in a transformer due to an internal fault, then
the blast of the explosion will be allowed to escape through the
explosion vent, rather than causing the transformer’s tank to explode.

Explosion Vent

1.3 Working Principle of Transformer

 The transformer works on the principle of Faraday’s Law of
electromagnetic induction and mutual induction.
 There are usually two coils – primary coil and secondary coil – on the
transformer core. The core laminations are joined in the form of strips.
The two coils have high mutual inductance.

10
 When an alternating current pass through the primary coil, it creates a
varying magnetic flux.
 As per Faraday’s law of electromagnetic induction, this change in
magnetic flux induces an EMF (electromotive force) in the secondary coil,
which is linked to the core having a primary coil. This is mutual induction.
 Overall, a transformer carries out the following operations:
 Transfer of electrical energy from one circuit to another
 Transfer of electrical power through electromagnetic induction
 Electric power transfer without any change in frequency
 Two circuits are linked with mutual induction

 The figure shows the formation of magnetic flux lines around a current-
carrying wire. The normal of the plane containing the flux lines is parallel
to the normal of a cross-section of a wire.

11
  The figure shows the formation of varying magnetic flux lines around a
wire wound. The interesting part is that the reverse is also true; when a
magnetic flux line fluctuates around a piece of wire, a current will be
induced in it. This was what Michael Faraday found in 1831, which is the
fundamental working principle of electric generators, as well as
transformers.

1.4 TYPES OF TRANSFORMERS

Transformers may be classified based on various aspects
 Based on construction
 Based on the transformer ratio
 Based on the core material
 Based on application
 Based on the cooling system
 Based on the type of supply
Based on construction: Based on how the transformer winding surrounds the core,
transformers may be classified into two types
 Core-type transformers: In such transformers, the windings are wrapped
around the core. The primary and secondary windings are wound around the
two different limbs of the core. It has two cylinders and two horizontal bars
forming the frame. The core has excellent magnetic properties and
maximum flux linkage between primary and secondary winding. Different
types of core plates such as E, I, U, and L shapes may be used as per
requirement.

12
  Shell-type transformers: In shell-type transformers, the core surrounds the
transformer winding. The primary and secondary windings are wound
around the central limb of the core. Such transformers use double magnetic
circuits and are suitable for high voltage low current applications due to poor
ventilation.

 Shell-type transformers use E-I and E-E laminations whereas core-type

transformers use L-L and U-I laminations.
Based on transformer ratio: Transformers may be classified based on the number
of turns in the primary and secondary.

13
  Step-Up Transformer: A step-up transformer is a type of transformer that
increases the voltage of an alternating current (AC). It has more turns in the
secondary winding than in the primary winding, which leads to an increase
in voltage.

For a step-up transformer, N2 > N1, V2 > V1 and I2 < I1 .

 Step-Down Transformer: A step-down transformer is a type of transformer

that reduces the voltage of an alternating current (AC). It has fewer turns in
the secondary winding compared to the primary winding. The primary
function of a step-down transformer is to decrease the voltage while
maintaining the same frequency as the input AC.

For a step-down transformer, N1> N2, V1 > V2 and I1 < I2 .

Based on Core Material: Transformers transfer electrical energy from one circuit to
another through electromagnetic induction over the core. The material used for
the core influences the flux density generated in the core. Accordingly, there are
several types of transformers based on the core material used.

14
  Iron Core Transformer: Such transformers use a stack of soft iron plates as
their core material. Transformers employing iron cores benefit from the
excellent magnetic properties of iron. Both primary and secondary coils are
wound around iron plates, creating a path for magnetic flux. The excellent
conductivity and magnetic properties of iron assure minimum resistance to
flux linkage. Therefore, iron core transformers are widely used due to their
higher efficiency compared to air core transformers.
 Ferrite Core Transformer: Such transformers use ferrite as core material.
These transformers are used for high-frequency applications such as RF
circuits and SMPS. The ferrite cores ensure minimum losses with high
frequency signals ensuring overall system efficiency. Ferrite core
transformers are flexible in shapes and sizes and can be custom-made for
specific needs. The most commonly used core is the E-shaped ferrite core.
 Air Core Transformer: Such transformers use air as the core material where
the primary and secondary winding are not wound to any magnetic material.
The magnetic flux generated due to the current in the primary winding flows
through the air. The mutual inductance produced by such transformers is low
compared to iron and ferrite core transformers.
Based on Application: A transformer may be used as a power transformer,
distribution transformer, instrument transformer, or autotransformer based on the
specific application for which it is used.
 Power Transformer: A power transformer converts low voltage, high current
electricity to high voltage low current electricity. They are usually employed
at generating stations and transmission substations to step down the power
to a desired level suitable for distribution to consumers.
 Distribution Transformer: Distribution transformers convert high grid voltage
to lower voltage for end users and form the final phase in the power
distribution system. They are either single-phase or three-phase
transformers and are available in various sizes to cater to various capacities.

15
  Instrument Transformer: An instrument transformer is also known as an
isolation transformer. It is used to isolate the secondary winding from the
primary winding when the primary has a high voltage and high current
supply. This transformer safeguards the measuring instrument or the energy
meter that is connected to the secondary of the transformer.
 Autotransformer: An autotransformer is a transformer with a single winding
that acts as both primary and secondary winding. Due to the single winding
configuration, it makes possible power transmission through electrical and
magnetic means. They are widely used in applications that need precise
voltage control such as laboratories and test benches.

Based on Cooling System: Based on the cooling methods used in transformers,

transformers are classified as
 Dry-type Transformer: A dry-type transformer is a type of transformer that
uses air or non-flammable solid insulation instead of liquid as a cooling
medium. Unlike oil-immersed transformers, dry-type transformers do not
require a liquid cooling agent such as mineral oil. Instead, they rely on
natural air convection or forced air circulation to dissipate heat generated
during operation.

16
  Oil-immersed Transformer: An oil-immersed transformer, also known as an
oil-filled transformer or liquid-filled transformer, is a type of transformer that
uses oil as both a cooling and insulating medium. The oil provides effective
heat dissipation from the transformer's core and windings while also serving
as an electrical insulator between the different components.

Based on Type of Supply: Based on the type of supply, transformers are classified
as single-phase and three-phase transformers.
 Single-Phase Transformer: A single-phase transformer is a type of
transformer designed to work with a single-phase alternating current (AC)
power supply. In a single-phase system, the voltage alternates in a sinusoidal
manner, completing one full cycle in a given period.

17
 Three-Phase Transformer: A three-phase transformer is a type of
transformer designed to work with a three-phase alternating current (AC)
power supply. In a three-phase system, three sinusoidal waveforms of
electric current or voltage are offset in time, creating a continuous and
balanced power flow. Three-phase power systems are commonly used in
industrial and commercial applications due to their efficiency in power
generation, transmission, and distribution.

18
 CHAPTER-2
TESTS ON A TRANSFORMER

2.1 Introduction

Testing a transformer is essential to ensure its safety, reliability, and

efficiency in electrical systems. Below are the key reasons why transformers are
tested:

 Verification of Design and Performance

 Preventive Maintenance and Reliability
 Safety Assurance
 Energy Efficiency
 Standards Compliance
 Health Monitoring Over Time
 Ensure Operational Reliability
 Minimize Energy Losses
 Meet Regulatory Standards
 Ensure Stability of Power Systems
 Validate After Repairs or Upgrades

19
2.2 Types of tests:

 Insulation Resistance Test

 Voltage Ratio Test
 Turns Ratio Test
 Magnetic Balance Test
 Magnetizing currents Test
 Short Circuit Test
 Open Circuit Test
 Back Feeding Test
 Winding Resistance Test
 Vector Group Test
 Oil BDV Test
Insulation Resistance Test:
The insulation resistance test is a key electrical test to assess the health of the
insulation in a transformer. It ensures that the insulation between the windings and
between the windings and core is intact, preventing leakage currents and potential
electrical hazards.

20
 Insulation Resistance Tester

 To measure the resistance of insulation material to detect moisture,

contamination, or degradation over time.
 To ensure safe operation by preventing short circuits and leakage currents.
 Between Primary and Secondary Windings
 Between Windings and Core (Earth)
 Between Primary Winding and Earth
 Higher resistance values indicate good insulation (typically in the range of
megaohms or higher).
 Lower resistance could indicate moisture ingress, contamination, or
insulation breakdown.
Voltage Ratio Test:
The voltage ratio test ensures that the ratio between the primary and secondary
winding voltages matches the design specifications. This test verifies that the
transformer will provide the correct output voltage under normal operating
conditions.
21
 Multimeter

 To confirm that the turns ratio between windings is correct and within
permissible limits.
 Ensures proper voltage transformation for the intended application.
 Apply a known AC voltage to the primary winding.
 Measure the output voltage on the secondary winding.
 Calculate the voltage ratio using the formula:
Voltage Ratio = V₁ / V₂
where V₁ = primary voltage, V₂ = secondary voltage.
 Compare the measured ratio with the nameplate ratio.
 The voltage ratio should be within a specified tolerance (e.g., ±0.5%) of the
design value.
 Any significant deviation may indicate issues like shorted turns or incorrect
winding connections.

22
Turns Ratio Test:
The turns ratio test checks the ratio of the number of turns between the
primary and secondary windings. This ensures the transformer delivers the
intended voltage transformation and operates efficiently.

Turns Ratio Tester

 To verify the turns ratio between windings matches design specifications.

 Identify potential issues such as shorted turns or incorrect winding
connections.
 Connect a low-voltage AC source to the primary winding.
 Measure the voltages on both primary and secondary windings.

23
  Calculate the turns ratio using:
Turns Ratio = V₁ / V₂
where V₁ = primary voltage, V₂ = secondary voltage.
 Compare the measured ratio with the rated turns ratio.
 The turns ratio should be within the tolerance range (e.g., ±0.5%) specified
by standards.
 Deviation indicates winding faults, short circuits, or manufacturing defects. 
Magnetic Balance Test:
The magnetic balance test checks the symmetry and health of the magnetic core
and windings in a three-phase transformer. It helps detect issues like core faults,
winding displacement, or shorted turns.

Multimeter

 To verify the balance in the magnetic circuit among the three phases.
 Detect core saturation, winding faults, or phase-to-phase imbalances.

24
 Apply single-phase AC voltage to one phase of the primary winding.
 Measure the induced voltages in the other two phases.
 Repeat the process by applying voltage to the remaining two phases
individually.
 Ideally, the induced voltages across phases should follow a pattern of V1 ≈
V2 + V3.
 Balanced readings indicate the magnetic circuit is healthy.
 Significant deviations suggest core issues, inter-turn faults, or winding
displacement.
Magnetizing Currents Test:
The magnetizing currents test measures the current required to energize the
transformer and establish the magnetic field in the core. This test helps assess
the health of the transformer’s core and the efficiency of its magnetic circuit.

Multimeter

 To determine the magnetizing current and assess the transformer's core

losses and overall magnetic characteristics.
 Identify any abnormalities in the core that could lead to inefficiencies or
overheating.

25
 Connect the transformer to a suitable voltage source, typically at the rated
voltage.
 Measure the current drawn by the transformer during the test while it is
under no-load conditions.
 Plot the magnetizing current versus the applied voltage to create a hysteresis
loop, if applicable.
 Analyze the magnitude and phase of the magnetizing current.
 The magnetizing current should be within the specified limits according to
the transformer’s design.
 Abnormally high magnetizing current may indicate core saturation, shorted
turns, or insulation issues.
Short Circuit Test:
The short-circuit test is performed to determine the transformer’s equivalent
circuit parameters, specifically its impedance, copper losses, and the voltage
drop under load conditions. This test simulates conditions that the transformer
may experience during fault scenarios.

Clamp Meter

26
 To measure the short-circuit impedance and calculate the copper losses
when the transformer is operating at full load.
 Assess the transformer's thermal and mechanical stability under fault
conditions.
 Short-circuit the secondary winding (usually by connecting it to a suitable
low-resistance load).
 Apply a low voltage to the primary winding while monitoring the current and
voltage.
 Measure the current, voltage, and power during the test.
 Calculate the impedance (Z) using: Z=VSCISCZ = \frac{V_{SC}}{I_{SC}}Z=ISC
VSC where VSCV_{SC}VSC is the voltage applied during the short circuit, and
ISCI_{SC}ISC is the short-circuit current.
 The impedance should fall within the design specifications.
Open Circuit Test:
The open circuit test (also known as the no-load test) is performed on
transformers to measure the core losses, determine the no-load current, and
evaluate the voltage regulation of the transformer. This test is essential for
understanding the transformer's performance when it is energized without a
load.

Clamp Meter

27
  To assess core losses (hysteresis and eddy current losses) when the
transformer is energized without any load.
 Determine the no-load current and the transformer's behavior under open
circuit conditions.
 Disconnect the secondary winding from any load to ensure it is open-
circuited.
 Apply the rated voltage to the primary winding while ensuring the secondary
is disconnected.
 Measure the current (I₀) flowing through the primary winding and the power
(P₀) consumed during the test.
 Calculate the core losses using the power measured during the test.
 The no-load current should be within the specified limits based on the
transformer's design.
 The core losses should also align with the manufacturer's specifications.
Back Feeding Test:
The back-feeding test is a diagnostic procedure used primarily for transformers to
assess their performance and operational integrity under reversed conditions.
This test is particularly relevant when evaluating transformers in systems where
they might experience reverse power flow, such as during maintenance or in
interconnected systems with distributed generation.

Multimeter

28
  To evaluate the transformer's ability to operate effectively when subjected to
reverse voltage or current flow.
 Ensure that protective devices and settings function correctly under back-
feeding conditions.
 Isolate the transformer from its normal power source and ensure it is safe to
test.
 Connect the transformer’s secondary winding to a power source capable of
supplying the rated voltage in the reverse direction.
 Monitor and record the input and output voltages, currents, and any
abnormalities during the test.
 Assess the transformer’s performance, including any changes in impedance,
efficiency, and heating characteristics.
 The transformer should handle the back-fed power without significant losses
or overheating.
 Voltage and current levels should remain within specified tolerances.
Winding Resistance Test:
The winding resistance test measures the electrical resistance of the transformer
windings to ensure they are in good condition and free from issues such as loose
connections, damaged conductors, or excessive heating. This test is essential for
evaluating the quality of the transformer windings and their ability to conduct
current effectively.
 To determine the resistance of both primary and secondary windings.
 Identify potential problems such as poor connections, overheating, or
winding faults.
 Disconnect the Transformer: Ensure that the transformer is de-energized and
isolated from the power source.

29
 Connect a Resistance Meter: Use a precision ohmmeter or a winding
resistance tester to measure the resistance across the windings.
 Measure Resistance: Apply the test across each winding (primary and
secondary) and record the resistance values.
 Temperature Correction: Since resistance varies with temperature, if the test
is performed at ambient temperature, use a formula to adjust the measured
resistance to a standardized temperature (usually 20°C or 25°C)
 The resistance values should align with the manufacturer's specifications.
 Significant deviations from expected values may indicate problems such as:
o Shorted turns within the winding.
o Loose connections or corrosion.
o Insulation deterioration.

Winding Resistance Meter

30
Vector Group Test:
The vector group test determines the wiring configuration and phase relationship
between the primary and secondary windings of a transformer. It is essential for
ensuring correct operation in systems where multiple transformers are connected
in parallel or when integrating transformers into a power system.
 To identify the vector group of the transformer, which indicates the phase
displacement and connection type (e.g., star (Y), delta (Δ), or other
combinations).
 Ensure compatibility with other transformers in parallel operation to prevent
circulating currents and phase angle mismatches.
 Disconnect the Transformer: Ensure the transformer is de-energized and
isolated from the power source.
 Identify Connection Points: Determine the connection points for the primary
and secondary windings.
 Apply Voltage: Connect a known voltage to one winding (typically the
primary) while the other winding remains open-circuited.
 Measure Phase Angles: Use a voltage measuring device or phase sequence
meter to measure the voltages across both windings.
 Calculate Phase Displacement: Analyze the phase relationship between the
voltages to determine the vector group (e.g., Yd11, Δy5, etc.).
 The vector group should match the transformer's nameplate rating.
 Any discrepancies may indicate improper winding connections or faults
within the transformer.
Oil BDV Test:
The Oil Breakdown Voltage (BDV) test of a transformer is a diagnostic procedure
used to assess the insulating properties of transformer oil. The BDV indicates the
voltage level at which the oil breaks down and conducts electricity, reflecting its
ability to withstand electrical stress.

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 Oil BDV Tester

Key Points:
 Purpose: To evaluate the dielectric strength of transformer oil, ensuring it
can effectively insulate the transformer windings.
 Procedure: A sample of the transformer oil is placed in a test cell, and
electrodes are submerged in the oil. An AC voltage is gradually applied until
breakdown occurs, which is indicated by a spark or arc between the
electrodes.
 Interpretation: Higher BDV values indicate better insulation quality. Low
values can signify contamination or degradation of the oil, necessitating
maintenance or replacement.
 Frequency: Regular BDV testing is recommended, especially in aging
transformers, to monitor the condition of the insulating oil and prevent
failures.

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 CHAPTER-3
CIRCUIT BREAKERS

3.1 Introduction:

Circuit breakers are essential devices in electrical systems, designed to

protect circuits from overloads and short circuits. They act as automatic switches
that interrupt the flow of electricity when an anomaly is detected, preventing
damage to equipment and reducing the risk of fire.

Circuit breakers are crucial components in electrical systems, serving as

automatic safety devices that protect circuits from overloads and short circuits.
They function by interrupting the flow of electricity when they detect fault
conditions, thereby preventing damage to equipment and reducing fire hazards.
Unlike fuses, which need to be replaced after blowing, circuit breakers can be reset,
offering convenience and cost savings. Various types exist, including Miniature
Circuit Breakers (MCBs) for low-voltage applications and Residual Current Circuit
Breakers (RCCBs) for earth fault protection. The reliable operation of circuit
breakers is vital for maintaining safety and efficiency in residential, commercial,
and industrial electrical installations, making them an indispensable part of modern
electrical engineering.

Circuit breakers are integral to electrical safety and system reliability,

functioning as the first line of defense against electrical faults. By automatically
interrupting the current flow during abnormal conditions, they mitigate risks
associated with overheating, equipment damage, and electrical fires.

33
3.2 Types of Circuit Breakers

Type Description
Air Circuit Uses air as the arc quenching medium. Typically used for
Breaker (ACB) low-voltage applications (up to 1 kV). Suitable for indoor
installations.
Oil Circuit Uses oil as both an insulator and an arc quenching medium.
Breaker (OCB) Mostly used in high-voltage systems, though becoming less
common.
SF₆ Circuit Uses sulfur hexafluoride (SF₆) gas to extinguish the arc.
Breaker Common in high-voltage applications because of excellent
insulating properties.
Air Blast Circuit Uses compressed air to blow out the arc. Mostly used in
Breaker high-voltage applications but has become less popular due
to the complexity of the air system.
Miniature Circuit Protects low-voltage circuits from overcurrent. Typically
Breaker rated up to 100 A.

Molded Case Used for higher currents (up to 2,500 A) than MCBs and
Circuit Breaker offers adjustable trip settings.
(MCCB)

Earth Leakage Detects leakage currents and disconnects power to prevent

Circuit Breaker electric shock.
(ELCB)

Residual Current Detects ground faults and disconnects power when leakage
Circuit Breaker currents are detected (more advanced than ELCB).
(RCCB)

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 CHAPTER 4
INSPECTION OF COILS

4.1 Introduction

There are two inspections that are carried out in the company
o 1st Inspection
o 2nd Inspection

1. Inspection of windings is necessary so that the weight and wire gauge of the
Coils are known visually.
2. The inspections are carried out in the presence of ADE of a particular area.
So that no mistakes would take place.
3. The values of the weights are further used in bill process.

The first inspection of windings in a transformer is a crucial step during

manufacturing, installation, or maintenance to ensure the windings are in good
condition. This inspection focuses on identifying any damage, contamination, or
issues that could compromise the transformer’s performance or longevity.

35
4.2 1st Inspection
 This inspection is carried out just after bringing the transformer for repair.
 The Transformer Tank is opened and oil is drained.
 Then the windings are taken out from the tank.
 The weight of both the LT and HT windings are checked using the Weighing
Machine and No. of coils are observed visually.
 Each coil is weighed and the weights are noted.
 Then the wire gauge is checked using the WIRE GAUGE WHEEL.
 The material used for winding is checked visually.

4.3 2nd Inspection

 This inspection is carried out after rewinding or re-insulation of coils.
 The weights of the coils are measured using Weighing Machine.
 No. of coils and weight of the coils should be equal to weights of 1st
Inspection.
 Point differences in the values of weights are allowed.
 The material used for winding should be same for both the inspections.
 Wire gauge also should be the same.

Wire gauge wheel

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4.4 Photos Collected from company
1st inspection in company:

2nd Inspection in company:

37
 CHAPTER 5
SINGLE PHASE TRANSFORMERS

5.1 Introduction
A single-phase transformer is an electrical device that transfers electrical
energy between two circuits through electromagnetic induction. It operates on
single-phase AC power, meaning the input and output are sinusoidal waveforms
with a single alternating voltage and current. These transformers are widely used in
low-voltage applications and in power distribution for residential and commercial
systems.

Single Phase Transformer

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5.2 Explanation

Basic Working Principle

 Electromagnetic Induction: When an AC voltage is applied to the primary
winding, it creates a changing magnetic field in the core. This magnetic field
induces a voltage in the secondary winding, transferring energy to the load.
 Turn Ratio: The ratio of the number of turns in the primary to the secondary
winding determines whether the transformer steps up (increases) or steps
down (decreases) the voltage.
Key Components
1. Primary Winding: Connected to the AC power source.
2. Secondary Winding: Connected to the load to supply the required voltage.
3. Core: Made of laminated steel to reduce energy losses and provide a path
for the magnetic flux.
Types of Single-Phase Transformers
1. Step-Up Transformer: Increases the input voltage (more turns on the
secondary winding).
2. Step-Down Transformer: Decreases the input voltage (fewer turns on the
secondary winding).
Applications
 Power distribution: Used in homes and small commercial buildings to step
down high voltage to a usable level (e.g., 240V to 120V).
 Appliances: Used in chargers, inverters, and other electrical devices.
 Lighting: Supplies low voltage for certain lighting systems.
 Medical equipment: Isolation transformers for safety in sensitive
environments.

39
Advantages
 Simple construction and easy maintenance.
 Reliable operation with fewer moving parts.
 Compact and efficient for low-power applications.
Limitations
 Only suitable for single-phase systems (cannot handle three-phase loads).
 Limited power handling capacity compared to three-phase transformers.

40
 CHAPTER 6
THREE PHASE TRANSFORMERS

6.1 Introduction
A three-phase transformer is an electrical device used to transfer
electrical energy between two three-phase systems through electromagnetic
induction. It operates on three-phase AC power, which consists of three
alternating currents, each phase separated by 120 degrees. These
transformers are essential for power transmission and distribution in
industries, commercial buildings, and power grids.

THREE PHASE TRANSFORMER

41
6.2 Explanation

Working Principle
 A three-phase transformer works on the same electromagnetic induction
principle as a single-phase transformer but handles three-phase power.
 It has three primary windings (one for each phase) and three secondary
windings, which may be connected in different configurations (like star or
delta).
 Depending on the turn’s ratio between the primary and secondary windings,
the transformer can either step up or step down the voltage.
Winding Configurations
1. Delta-Delta (Δ-Δ):
o Both primary and secondary are connected in a delta configuration.
o Suitable for high currents and industrial applications.
2. Star-Star (Y-Y):
o Both primary and secondary are in a star configuration.
o Provides a neutral point, useful for systems requiring neutral
grounding.
3. Delta-Star (Δ-Y):
o Primary in delta, secondary in star.
o Common in power distribution networks, stepping down high
transmission voltages.
4. Star-Delta (Y-Δ):
o Primary in star, secondary in delta.
o Used to step up voltages in generation stations for transmission.

42
Applications
 Power Transmission: Transforms voltage levels for efficient transmission
over long distances.
 Power Distribution: Steps down voltage for commercial and industrial use.
 Industrial Equipment: Supplies power to motors and machines requiring
three-phase power.
 Renewable Energy Systems: Used in wind and solar power plants for voltage
conversion.
Advantages
 Efficient Power Transmission: Three-phase systems are more efficient and
balanced compared to single-phase systems.
 Compact Design: A single three-phase transformer can replace three single-
phase transformers.
 High Power Handling: Can transmit and distribute large amounts of power.
Limitations
 Higher Cost: More expensive than single-phase transformers.
 Complex Design: Requires more insulation and precise winding.
 Maintenance Challenges: Faults in any phase can affect the entire system.
Conclusion
Three-phase transformers are indispensable in modern power systems,
ensuring efficient and reliable power transmission and distribution. Their ability to
handle large loads makes them essential for industrial, commercial, and utility
applications.

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 CHAPTER 7
MACHINES IN THE COMPANY

7.1 Introduction
We use many machines in the company for the work needed for a complete
Transformer repairing. In a transformer repair company, various specialized
machines and equipment are used to diagnose, repair, test, and maintain
transformers. These machines ensure that transformers are restored to optimal
working condition, addressing issues like winding faults, insulation breakdown, oil
contamination, and electrical malfunctions.

7.2 Explanation

 Winding Machines
 Purpose: Used to rewind or repair damaged transformer windings.
 Functionality: Precisely winds copper or aluminum conductors to
create or repair transformer coils.
 Types: Automatic winding machines for high precision, and manual
winding machines for small repairs

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LT Winding Machine:
An LT (Low Tension) winding machine is specialized
equipment used in transformer manufacturing and repair to wind the
low-voltage (LV) or low-tension (LT) windings. These windings
typically handle lower voltages, such as 415V or 230V, in transformers.
The LT winding machine ensures precise winding of conductors (such
as copper or aluminum) around a transformer core, which is essential
for maintaining the efficiency and performance of the transformer.

LT Winding Machine

Process of Winding
1. Setup: The bobbin or core is mounted on the spindle, and the
conductor wire is fed through the guide.
2. Parameter Input: The operator sets the number of turns, speed,
and tension (if automatic).
3. Winding: The machine rotates the spindle, and the wire is wound
around the core according to the set parameters.
4. Completion: The machine stops automatically or manually when
the required turns are completed.
5. Inspection: The winding is checked for accuracy and consistency
before assembly.
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HT Winding Machine:
An HT (High Tension) winding machine is specialized equipment used
to wind the high-voltage (HV) or high-tension (HT) windings in transformers.
HT windings handle higher voltages (such as 11kV, 33kV, or higher) compared
to LT windings, requiring precise winding techniques to ensure insulation
reliability and electrical performance. These machines are critical in
transformer manufacturing and repair, ensuring the quality, accuracy, and
durability of the windings.

HT Winding Machine

Process of Winding:
1. Setup: Mount the core or winding mandrel on the spindle, and
thread the conductor through the guide.
2. Parameter Configuration: Set the number of turns, speed, and
insulation intervals on the control panel.
3. Winding Process: Start the machine to wind the conductor
around the core under constant tension.
4. Insulation Layering: Apply insulation between winding layers
(manually or automatically).
5. Completion and Inspection: The machine stops when the
required turns are complete, and the winding is inspected for
uniformity and tightness.

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 Oil Filtration Machines

Oil filter machine

 Purpose: Purifies transformer oil by removing moisture,

dissolved gases, and impurities.
 Functionality: Restores the dielectric strength of the oil,
improving the transformer’s performance and longevity.
 Examples: Centrifugal oil purifiers and vacuum dehydration
systems.
 LT Insulation Machine
An LT (Low Tension) insulation machine is specialized equipment used in
the manufacturing and repair of transformers to apply insulating material
(such as paper, polyester film, or varnish) between layers of low-voltage
windings. Proper insulation is critical in transformers to prevent electrical
faults like short circuits between turns or layers and to enhance the
dielectric strength of the windings.

LT Insulation Machine
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 Core Cutting Machines
 Purpose: Cuts or reshapes the laminated cores used in
transformers.
 Functionality: Ensures precise cutting of core materials like
silicon steel, minimizing losses.
 Usage: Used in repair or refurbishment of transformer cores.
 Testing Machines and Instruments
 Transformer Turns Ratio (TTR) Tester: Measures the turn ratio
between the primary and secondary windings.
 Insulation Resistance Tester (Megger): Checks insulation health
between windings and between windings and core.
 High Voltage Testers (Hipot): Verifies the insulation strength by
applying high voltage.
 Welding and Brazing Machines

Welding Machine
 Purpose: Repairs damaged transformer tanks and re-connects
winding leads.
 Usage: Used for sealing leaks in transformer tanks and
performing electrical joint repairs.
48
 Power Supply and Load Test Machines
 Purpose: Simulates real-world conditions to test transformer
performance after repairs.
 Functionality: Applies voltage and current loads to ensure the
transformer meets specifications.
 Usage: Helps to prevent overheating during load tests.
 Cranes and Lifting Equipment
 Purpose: Lifts heavy transformer components, such as cores,
tanks, and windings, during disassembly and reassembly.
 Types: Overhead cranes, hoists, and forklifts.

 Heating Chamber
A heating chamber (also called a drying oven or baking oven) is
essential equipment used in transformer repair facilities to remove
moisture and impurities from transformer windings, insulation, and other
internal components. This process is critical to maintain the dielectric
strength and operational efficiency of the transformer.

49
 Heating Chamber

1. Moisture Removal:
 During repairs, windings and insulation materials may absorb
moisture from the air, which can degrade the transformer's
performance.
 The heating chamber removes moisture from paper insulation,
windings, and cores, preventing breakdown and electrical
failures.
2. Curing and Baking:
 Ensures proper curing of insulation varnishes or resins applied
to windings after repairs.
 Prevents air pockets in insulation, which could cause partial
discharges during operation.
Process of Using a Heating Chamber
1. Placement of Components:
o Transformer windings, cores, and other parts are placed
inside the chamber.
50
 2. Heating Cycle:
o The chamber is heated to the required temperature, and
the components are kept inside for several hours.
3. Monitoring:
o Sensors monitor temperature and humidity levels to ensure
the drying process is effective.
4. Cooling Phase:
o After the heating cycle, components are slowly cooled
before further assembly or oil filling.

7.3 Conclusion
The machines used in a transformer repair company are designed for
precision diagnostics, repairs, and testing. These tools ensure transformers are
restored to working order, maintaining safety, efficiency, and reliability. Effective
use of these machines minimizes downtime and extends the operational life of
transformers.

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 CHAPTER 8
PROCEDURE OF REPAIRING TRANSFORMER

8.1 Introduction
Transformer repair is a critical process aimed at restoring the functionality
and reliability of faulty or damaged transformers. Transformers can experience
failures due to insulation degradation, mechanical damage, oil contamination,
moisture ingress, electrical overloads, or short circuits. Repair ensures the
transformer is brought back to optimal working condition, preventing costly
downtime and maintaining system efficiency.

8.2 Steps Involved in Transformer Repair

1. Initial Inspection and Testing
o Visual inspection to identify signs of burn marks, leakage, corrosion, or
physical damage.
o Electrical testing to assess parameters such as:
 Insulation resistance (using a Megger)
 Transformer Turns Ratio (TTR)
 Winding resistance and continuity
 High-voltage withstand test (Hipot test)
o The results help determine whether the transformer needs repairs,
rewinding, or oil purification.
2. Dismantling of Transformer Components
o The transformer is de-energized and disassembled to access windings,
core, insulation, and other internal parts.

52
 o Oil is drained if the transformer is oil-filled, and the parts are cleaned
to remove sludge or contaminants.
3. Winding Repair or Rewinding
o If the windings are damaged due to overheating or short circuits, they
are rewound or repaired.
o LT or HT winding machines are used to wind new coils accurately,
ensuring proper tension and insulation.
o Insulation materials (such as Kraft paper or varnish) are applied
between winding layers to maintain dielectric strength.
4. Core Repair and Assembly
o The magnetic core is inspected for any deformities or damage.
Damaged core laminations are replaced to reduce energy losses.
o Proper alignment of the core ensures low magnetizing currents and
prevents vibration or noise issues.
5. Replacement of Insulation and Sealing Materials
o Old or degraded insulation between windings and cores is replaced to
restore electrical strength.
o Gaskets, seals, and bushings are checked for wear and replaced if
necessary to avoid oil leakage.
6. Transformer Oil Filtration or Replacement
o Transformer oil plays a critical role in cooling and insulation.
Contaminated oil is filtered to remove moisture, dissolved gases, and
impurities.
o In some cases, the oil is replaced entirely to ensure proper
performance.
7. Reassembly and Vacuum Drying
o The repaired components are reassembled, and the transformer is
placed in a vacuum drying chamber to remove any remaining moisture
from the windings and insulation.
53
 o This step ensures that the insulation retains its dielectric properties.
8. Testing After Repair
o The repaired transformer undergoes a series of tests to ensure it
meets operational standards:
 Turns Ratio Test: Ensures proper voltage transformation
between windings.
 High Voltage Test (Hipot): Verifies insulation integrity.
 No-Load Test and Load Test: Checks performance under typical
operating conditions.
 Leakage Test: Ensures there are no oil or coolant leaks.
9. Painting and Final Assembly
o The external tank and parts are cleaned and painted to prevent
corrosion.
o Final assembly includes proper installation of bushings, terminals, and
seals.
10.Installation and Commissioning
 The repaired transformer is transported back to its site, installed, and
reconnected to the network.
 After energizing, the transformer is monitored for a few days to
ensure it operates correctly without overheating, noise, or voltage
irregularities.

54
8.3 Common Transformer Repair Scenarios
 Winding Failure: Caused by short circuits or overloading.
 Core Damage: Results from mechanical stress or improper assembly.
 Insulation Breakdown: Due to moisture ingress or aging.
 Oil Contamination: Leads to reduced dielectric strength.
 Bushing Failure: Caused by mechanical stress or flashover.

8.4 Advantages of Transformer Repair

 Cost Savings: Repairing a transformer is more economical than replacing it
with a new one.
 Extended Lifespan: Proper repair restores the transformer’s operational
lifespan.
 Reduced Downtime: Faster restoration helps avoid extended outages in
power networks.
 Environmentally Friendly: Repair minimizes waste and promotes
sustainability by reusing components.

8.5 Conclusion
Repairing transformers is an essential part of power system
maintenance, ensuring that faulty units are restored to safe and efficient
operation. With proper diagnostic tools, rewinding machines, and skilled
technicians, transformer repair can extend the lifespan of transformers,
reduce downtime, and maintain the reliability of power networks.

55
CONCLUSION
In the realm of transformers, the intertwined processes of repair and manufacturing
played pivotal roles in ensuring the reliability, efficiency, and sustainability of
power systems. The continuous evolution of transformer technology is driven by a
commitment to addressing emerging challenges, enhancing performance, and
embracing environmental consciousness.

Transformer repair stands as a critical facet in the life cycle management of these
indispensable devices. With aging infrastructure and the demand for extended
operational lifespans, the refurbishment of transformers becomes essential. The
utilization of advanced diagnostic tools and techniques allows for precise
identification of faults, enabling targeted repairs and preventive maintenance. As
we move forward, a proactive approach to transformer repair, guided by
predictive analytics and real-time monitoring, is set to minimize downtime,
optimize asset utilization, and extend the service life of transformers.

Simultaneously, the landscape of transformer manufacturing is undergoing a

transformation characterized by innovation, sustainability, and digitalization. The
integration of smart technologies, such as sensors and loT, into the
manufacturing process enhances quality control, facilitates customization, and
lays the foundation for smart grids. Advanced materials, including
superconductors and eco-friendly insulating fluids, are poised to revolutionize
transformer efficiency and environmental impact.

56