Sai Tech

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

 BONIFIDE CERTIFICATE

This to certify that the Industrial Training Report is a bonified record of Mr. T.SAI
bearing PIN NO. 22637-EE-057 of final year DEEE 2023-2024 along the
batchmates in partial fulfilments for award of Diploma in Electrical & Electronic
Engineering, State Board of Technical Education and Training, Andhra Pradesh
during academic year 2024-2025

GUIDE HEAD OF THE SECTION PRICIPAL

A.Ramesh B.SESHA SAI Dr.N.CHANDRA SHEKHAR

M.TECH,PhD
 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
A transformer is a passive component that transfers electrical energy from one
electrical circuit to another circuit, or multiple circuits. Transformers are used to
change AC voltage levels, such transformers being termed step-up or step- down
type to increase or decrease voltage level, respectively. Transformers can also be
used to provide galvanic isolation between circuits as well as to couple stages of
signal processing circuits. There are different varieties of transformers in the market
right now that serve different purposes. From dry-type to oil- type, the options for
what kind of transformer you use. An oil-type transformer is a kind of transformer
that uses oil as a cooling and insulating medium. The core and coils of an oil-type
transformer are immersed in oil, which helps to cool the transformer and provides
insulation. An oiltype transformer consists of the following parts: Core, Coils,
Insulating Materials, Transformer Oil, Tank, Tap Changer, Bushings, and
Ventilation. The oil in oil-cooled transformers effectively cools the transformer
because it has a high heat capacity and high thermal conductivity. These
transformers are non-flammable and has a high flash point. Another advantage is its
long lifespan, also durable and can withstand a lot of wear and tear. These
transformers can withstand high voltages without breaking down.
 INDEX

S.NO. NAME OF THE CONTENT

Chapter-01 INTRODUCTION
Chapter-02 TRANSFORMERS
Chapter-03 SINGLE PHASE TRANSFORMERS
Chapter-04 THREE PHASE TRANSFORMERS
Chapter-05 TYPES OF MACHINES
Chapter-06 CORE
Chapter-07 CORE HEATING OVEN
Chapter-08 MEGGER
Chapter-09 WINDING
Chapter-10 TYPES OF CONNECTIONS
Chapter-11 METERS
Chapter-12 BUSHINGS
Chapter-13 LIGHTNING ARRESTORS
Chapter-14 CRANE & CRANE OPERATING SYSTEM
Chapter-15 PHASE POWER ANALYSER
Chapter-16 PAPER ROLL AND TYPES
Chapter-17 PAINT
Chapter-18 PROCESS OF REPAIRING TRANSFORMERS

 CONCLUSION
CHAPTER-1
 Introduction
The transformer is a device used for converting a low alternating voltage to a high
alternating voltage or a high alternating voltage into a low alternating voltage. It is a
static electrical device that transfers energy by inductive coupling between its
winding circuits. Transformers range in size from a thumbnail-sized coupling
transformer hidden inside a stage microphone to huge units weighing hundreds of
tons used in power plant substations or to interconnect portions of the power grid.
All operate on the same basic principles, although the range of designs is wide.
While new technologies have eliminated the need for transformers in some
electronic circuits, transformers are still found in many electronic devices.
Transformers are essential for high- voltage electric power transmission, which
makes long-distance transmission economically practical. A transformer is most
widely used device in both low and high current circuit. In a transformer, the
electrical energy transfer from one circuit to another circuit takes place without the
use of moving parts. A transformer which increases the voltages is called a step-up
transformer. A transformer which decreases the A.C. voltages is called a step-down
transformer. Transformer is, therefore, an essential piece of apparatus both for high
and low current circuits.
CHAPTER-2
TRANSFORMER :

Transformer is a static device for transforming electrical energy from one circuit to another circuit
without any chance in frequency.

Purpose of transformer:

The purpose of using a transformer in power supply is to make electrical power accessible as it
travels from a power utility to an office, home, worksite or other location. Energy is lost when it
travels along transmission wires from a power plant to a customer. Utilities use a very high voltage
to lose less energy.

Theory of transformer:

A transformer works on the principle that energy can be transferred by magnetic induction from
one set of coils to another set by means of a varying magnetic flux. The magnetic flux is produced
by an AC source.

Function of transformer:

Transformers are used in electric circuits to change the voltage of electricity flowing in the circuit. It
is used to increase the voltage (called 'stepping up') or decrease the voltage ('stepping down') in
AC circuits

TRANSFORMER:-
Transformer is a static device for transforming electrical energy from one circuit to another circuit
without any chance in frequency,

Types of single-phase transformers:

1. Step-up transformer

2. Step-down transformer

Step-up transformer: The secondary voltage will be more than primary voltage and such a
transformer is known as step-up transformer.

Step-down transformer: The secondary voltage will be less than primary voltage and such a
transformer is known as step-down transformer any chance in frequency.

TRANSFORMER LOSSES:-

The output energy of a transformer is always less than the input energy, because energy losses
occur due to a number of reasons as explained below

1. Loss of Magnetic Flux: The coupling between the coils is seldom perfect. So, whole of the
magnetic flux produced by the primary coil is not linked up with the secondary coll.

2. Iron Loss: In actual iron cores in spite of lamination, Eddy currents are produced. The
magnitude of eddy current may, however be small. And a part of energy is lost as the heat
produced in the iron core

3. Copper Loss: In practice, the coils of the transformer possess resistance. So a part of the
energy is lost due to the heat produced in the resistance of the coil.

4. Hysteresis Loss: The alternating current in the coil tapes the iron core through complete
cycle of magnetization. So Energy is lost due to hysteresis.

5. Magneto restriction: The alternating current in the Transformer may be set its parts in to
vibrations and sound may be produced. It is called humming. Thus, a part of energy may be lost
due to humming.
CHAPTER-3
Construction of a single-phase transformer:
Transformer essentially consists of two windings, which are wound on a common laminated
magnetic core. The core is made with soft iron of silicon steel laminations to provide a path of low
reluctance for the magnetic flux. The windings are insulated from both core and each other The
winding which is connected to supply mains is known as "primary winding" and the winding
connected to the load circuit is known as "secondary winding There is no electrical or mechanical
connection between the two windings, but there is a magnetic linkage between the two For the
sake of simplicity and for analysing transformer theory the two windings are shown on opposite
sides of the core But in actual construction the two windings are wound one over the other.

Working of single-phase transformer:-

When the primary winding is connected to an acc. supply source of voltage VI' and frequency
hertz, a current '11' will flows through it. This current produces an alternating flux 'D' in the core
which varies with time. This flux first links with primary winding hence produces self induced e.m.f
“E1” in the primary winding which opposes the applied voltage. The e.m.f sometimes known as
known as back e.m.f of the primary.

The flux '' passes through the magnetic core, and links with secondary winding also, so induces an
e.m.f. called mutual induced e.m.f 'E2' in the secondary winding. The magnitude of e.m.f. induced
is proportional to the rate of change of flux linkages and number of turns. The frequency of the
e.m.f. induced In the secondary winding is same as that of the flux or that of

supply voltage. The emf. in the secondary winding will able to circulate the current '12' in the load
circuit. Thus the energy is transferred from primary winding to the secondary winding through the
medium of magnetic field by electromagnetic induction principle without any change in frequency.

Construction details of transformer:

1. Core 2. Windings

3. Tank 4.Transformer oil

5. Conservator 6. Breather

7. Terminals and bushings

8. Exhaust pipe, oil guage, temperature guage.

9 cooling system Core:

The transformer core provides a magnetic path to channel flux. The use of highly permeable
material (which describes the material's ability to carry lux), as well as better core construction
techniques, helps provide a desirable, low reluctance flux path and confine lines of flux to the core.
The core is constructed of numerous thin strips of grain-oriented silicone steel, called laminations,
which are electrically isolated (yet still magnetically coupled) from each other by thin coatings of
insulating material. This is important to reduce the no-load losses of the transformer. The core is a
source of heat in the transformer and as a core increases in size, cooling ducts within the core
may become necessary. Problems such as short-circuited core laminations will result in increased
losses and possibly overheating of the transformer core.

Windings:

The winding are made with copper conductor and are placed on the cores. The winding which is
connected to supply is known as primary and the winding which is connected to load is known as
secondary winding. The winding which is connected to low voltage is known as low voltage
winding LV and the winding which is connected to high voltage HV is known as high voltage
winding.

Tank:

Transformers are generally housed in a tightly fitted sheet metal tanks filled with special insulation
Oil The core winding are completely immersed in the Oil inside the tank In case small
transformers, the tanks are made with iron sheets or sheet steel, whereas in case of large
transformers, the tanks are made with plain boiler plates or cast aluminum plates. The sheets or
plates are properly welded and a waterproof gasket being used at the joints so the oil may not
come out of tank. When the transformer is winding. Heat is produced in the tank hence needs
cooling.

For cooling purpose, cooling tubes are welded around the tank in case of large transformers
separate radiator are welded to the tank which provides better cooling. A tank must be also to
withstand the stresses developed inside and has provision for connecting to the load and supply

TRANSFORMER OIL:
The insulation oil which is used in the tank of a transformer is called transformer oil it has three
functions.

1. It acts as insulation medium between windings and tank

2. It provides better cooling by correcting through the cooling tunes

3. It carries away the heat generated in the core and windings and quenches the arc if any.

CONSERVATOR:
It is a small oil tank mounted about the transformer and connected to the main tank by a pipe The
oil level of a transformer changes with change in temperature of oil which in turn depend upon the
load on the transformer. The conservator receives the increased volume of Oil during expansion
and discharged the oil during contraction and keeping the main tank full of oil The conservator is
not filled completely with oil to facilitate the expansion. As it receives the oil during expansion it is
also called as expansion tank.
BREATHER:
A breather consists of a silica gel crystal or CaC12 and is connected to

the conservator through vent pipe. The silica gel absorbs the moisture

from the air and clean moisture less air is allowed into the transformer.

Silica gel is blue in color when dry and becomes whitish pink when it

absorbs moisture in sufficient quantity. When silica gel changes into

whitish pink, it should be replaced. The color can be observed through

the glass window provided in front of the breather.

TERMINAL AND BUSHINGS:

The connections to the windings are copper rods or bars insulated from the tank the windings are
connected to the HV and LV line's through insulator bushing mounted on the top of transformer
tank the bushing consist of a Current carrying element and a porcelain cylinder upto 33KV voltage
ordinary porcelain insulator are used and above 33KV oil filled orcondenser type bushings are
used.

Exhaust pipe, oil guage, temperature guage:

Many transformers are provided with exhaust pipe made of steel. It's connected to the tank and
has some bend at its end and is provided with a glass disc at top. It protects the tank from the
large expansion of the accidental gas formation in large quantity and abrupt rise in pressure in
case of short circuit etc. Every transformer is provided with oil gauge and temperature gauges Oil
gauge indicates the level of oil in the tank. The oil gauge is also provided with an alarm which
gives an alarm when the oil level has dropped below certain level due to oil leak. The temperature
gauge indicates the temperature of the oil.
Cooling system:
Whenever current is flowing through the windings, heat is produced which should be dissipated. If
the heat is not dissipated properly, it may damage the windings end insulation. Hence, cooling is
necessary for a transformer, which can be provided by different methods such as natural air
cooling, oil immersed forced air, water and oil cooling and air- blast cooling.
CHAPTER-4
Three Phase Transformer:-
A three-phase transformer consists of three primary coils and three secondary coils and is
represented as 3-phase or 34. A three-phase system can be constructed using three individual
identical single-phase transformers, and such a 3-phase transformer is known as the bank of three
transformers. On the other hand, the three-phase transformer can be built on a single core The
windings of a transformer can be connected in either delta or wye configurations. The working of
the 3-phase system is similar to a single-phase transformer, and they are normally employed in
power generation plants.

Construction:-
A Three-phase transformer of a single unit is used widely because it is lighter, cheaper and
occupies less space than the bank of three single-phase transformers. The three-phase
transformer construction is of two types: Core type and Shell type.

Core Type Transformer:

In this type of construction, there are three cores and two yokes. Each core has both primary and
secondary windings wounded spirally as shown in the figure. Each leg of the core carries high
voltage as well as low voltage windings. The core is laminated to minimize eddy current losses on
core and yoke. As it is easier to laminate low voltage (LV) winding than the high voltage (HV)
winding. The LV windings are positioned near the core with appropriate insulation and oil ducts in
between them whereas, the HV windings are placed above the LV windings with appropriate
insulation and oil ducts between them.

Shell Type Transformer:

The three-phase shell type transformer is generally constructed by stacking three individual
simplephase transformers. Three phases of a shell-type transformer are independent than the
core-type transformer, while each phase has an individual magnetic circuit. These magnetic
circuits are parallel to each other and flux induced by cach winding is in phase Shell type
transformer is highly preferred as the voltage wave forms are less distorted

Working of 3-Phase Transformer

The primary winding of the three phase transformer is energized from a three phase supply. Then,
the flux is produced in the core by the primary currents in the three windings. The core has three
limbs, where any two limbs act as return path for the flux in the third lamb. The flux produced by
the primary windings induces emf in the secondary windings depending on the transformation ratio
of the 3-phase transformer

Three-Phase Transformer Connections

There are two three-phase windings in a three-phase transformer, primary winding and secondary
winding.

The connection of primary winding and secondary winding can be a star or delta connection.
According to the application of a transformer, the primary winding and secondary winding can be
connected in four possible configurations as follows:

• Delta-Delta (A-A)

• Star-Star (Y-Y)
 • Delta-Star (A-Y)

• Star-Delta (Y-A)

Delta-Delta (A-A) Connection:

In the delta-delta transformer connection, primary and secondary are connected in the
Delta connection
This connection is generally used even if the lead is unbalanced and for large, low-voltage
transformers. The number of required phases/turns is relatively greater than that for star-star
connection.

The ratio of line voltages on the primary and secondary sides is equal to the transformation ratio of
the transformers.

Besides that, this connection is that even if one transformer is disabled, the system can continue
to operate in an open delta connection but with reduced available capacity.

Star-Star (Y-Y) Connection

In this connection, the primary winding and secondary winding are connected in a star connection.

This connection is generally used only if the connected load is balanced for small, high voltage
transformers. Because of the star connection, the number of required turns/phase is reduced (as
phase voltage in star connection is 1/43 times of line voltage only). Therefore, the amount of
insulation required is also reduced.

The ratio of line voltages on the primary side and the secondary side is equal to the transformation
ratio of the transformers.

Line voltages on both the primary side and the secondary side are in phase with each other.

Delta-Star (A-Y) Connection

In a Delta-star connection of a three-phase transformer, the primary winding is connected in a

Delta connection, and the secondary winding is connected in a star connection.

The primary winding is connected in a Delta connection. Therefore, in the primary winding, the
phase voltage is equal to the line voltage.

The secondary winding is connected in a star connection. Therefore, in the secondary winding. the
line voltage is √3 times the phase voltage.
The primary winding is connected in the delta and the secondary winding is connected in the star
with neutral ground. Therefore, it can be used to provide a 3-phase 4-wire service.

This connection is mainly used in a step-up transformer at the beginning of the transmission line.

The ratio of secondary to primary line voltage is 13 times the transformation ratio Thure is a 30
shift between the primary and secondary line voltages.

Star-Delta (Y-A) Connection

In a star-delta connection, the secondary winding is connected in a delta configuration primary
winding is connected in a star configuration
The secondary winding is delta connected and the primary winding is star star (Y) connected with
grounded neutral,
This star-delta connection is mainly used in step-down transformers at the substation end of the
transmission line.
The ratio of secondary to primary line voltage is 1/43 times the transformation ratio. There is a30°
shift between the secondary and primary line voltages.

Advantages of transformer:
• A transformer will increase or decrease basically AC voltage, current It is efficient for
highfrequency range
• The available power cannot change but will slightly too much decrease depending on the
efficiency of the transformer
• It has the advantage of preventing condensed flux leakage as well as iron loss
• It offers good mechanical strength
• The transformer is widely used in power transmission

Disadvantages of transformer:-
• A transformer will not work with DC voltage under any condition.
• The transformer size becomes un widely
• The physical size of the transformer is directly related to the amount of power to be desired.
• It is not good to use outdoors.
• It can be noisy.

APPLICATIONS OF TRANSFORMERS:-

• A transformer is used in almost all a.c. operations

• In voltage regulator for TV refrigerator, computer, air conditioner etc.
• In the induction furnaces.
 • A step down transformer is used for welding purposes
• A step down transformer is used for obtaining large current
• A step up transformer is used for the production of X-Rays and NEON advertisement
• Transformers are used in voltage regulators and stabilized power supplies
• Transformers are used in the transmissions of a.c. over long distances
• Small transformers are used in Radio sets, telephones, loud speakers and electric bells etc.

Uses of transformer:

Transformers can be used to change the voltage and current in an electrical circuit or to change
the impedance of a circuit. Transformers are used in a variety of applications, including power
generation, transmission and distribution, lighting, audio systems, and electronic equipment.

AMPHOROUS TRANSFORMER:-

Amorphous core transformers are manufactured using ferromagnetic amorphous metal formed
into thin foils. Their higher resistance and thinner foils have been proven to lead to low losses and
better resistance to harmonic wave
Fig: Amorphous core
CHAPTER-5
OIL FILTRATION MACHINE:
Transformers play a vital role in the effective functioning of
power system transmission and distribution network.
Therefore the operating condition of the transformers have
to be checked periodically to ensure reliable service and
considered to an important check point in transformer oil
filtration system The efficiency of transformer depends on
the insulation materials used during the manufacturing of
the transformer.
The oil insulation deployed in the power transformers is
used to transfer the heat developed inside the transformer
core and windings and also be able to withstand the stress
due to heavy loading and short circuit. Transformer oil
storage tanks are required to store contaminated clean oil so that the same can be used as and
when it is required.

OIL DETERIOTATION:
Overtime due to continued operation of the transformer the insulating oil in the transformer gets
deteriorated by oxidation and thermal by products that get deposited in the oil. These ageing
products formed may cause severe breakdown of the transformer leading to heavy interruptions in
the power supply. There arise the demand of preventative maintenance actions to be taken timely
to avoid any unexpected outages in the network. The maintenance of the transformer includes the
fact of improving the quality of the insulating oil which in turn increases the life span of the
transformer.

HV winding machine:-
consists of a rotating spindle or mandrel, on which the transformer
core is mounted. The core is rotated at a controlled speed while the
wire is fed onto the core, creating the winding. The wire is typically
fed from a spool or reel and is guided onto the core by a series of
guides and tensioning devices.
The HV winding machine is capable of winding wire of varying
thicknesses, depending on the specific requirements
of the transformer being manufactured. The machine must be
capable of maintaining a consistent tension on the wire throughout
the winding process, to ensure that the resulting coil is uniform and
of high quality
In addition to the winding process, the HV winding machine may also
be equipped with other features such as wire cutters, insulation application devices, and
temperature sensors. These features are designed to aid in the manufacturing process and
ensure that the resulting transformer is of high quality and reliability
Overall, the HV winding machine is a critical component in the manufacturing of high-voltage
transformers, and plays a key role in ensuring the reliability and performance of these important
electrical components
LV winding machine:-
An LV (Low Voltage) winding machine is a specialized machine used in the manufacturing of
low-voltage transformers. These machines are designed to wind coils of wire around a core,
creating the low-voltage winding of a transformer.
The LV winding machine typically consists of a rotating spindle or
mandrel, on which the transformer core is mounted. The core is rotated
at a controlled speed while the wire is fed onto the core, creating the
winding. The wire is typically fed from a spool or reel and is guided onto
the core by a series of guides and testing devices Paper cutting
machine :
A paper cutting machine, also known as a paper cutter or
guillotine cutter, is a device used to cut sheets of paper into
smaller sizes or shapes Paper cutting machines can be
manual, semi-automatic, or fully automatic, and are used in
a variety of industries including printing, publishing, and
packaging
Manual paper cutting machines are operated by hand, and
typically consist of a blade mounted on a lever arm. The
operator places the stack of paper to be cut on a cutting
surface, and then brings the blade down onto the paper
using the lever arm. This type of machine is suitable for
cutting small quantities of paper, but can be tiring to use for larger jobs. Semi-automatic paper
cutting machines are powered by electricity and are operated using a foot pedal or button. These
machines typically have a larger cutting capacity than manual machines, and may also feature
additional cutting options such as angled cuts or perforations Precautions:
Safety is an important consideration when using paper cutting machines, as the blades can be
very sharp and can cause serious injury if not used properly. It is important to follow all safety
guidelines and to ensure that the machine is properly maintained and inspected on a regular
basis. The LV winding machine is capable of winding wire of varying thicknesses. depending on
the specific requirements of the transformer being manufactured. The machine must be capable of
maintaining a consistent tension on the wire throughout the winding process, to ensure that the
resulting coil is uniform and of high quality.

AIR TEMPERATURE MACHINE:

As the name itself says that both the oil and the air are applied by force for
cooling of a transformer The Heat Exchanger is installed through which
hot oil is circulated with the help of a pump. Air is forced to pass on the
heat exchanger with the help of high-speed fans
CHAPTER-6
Core:
The purpose of core is to provide a path of low reluctance for themagnetic flux. it is made with with
silicon steel laminations. The purpose of laminating the core in to reduce Eddy current loos These
laminations are made with silicon steel to reduce hysteresis loss, because silicon steel has low
hysteresis co- efficient. The laminations are insulating from each other by means of varnish or
impregnated paper or enamel.

Different types of cores:

3PHASE CELL TYPE CORE 3PHASE AMORPHOUS TYPE CORE

3PHASE CRGO TYPE CORE

Purpose of Core:
In an electrical power transformer, there are primary, secondary and may be tertiary windings The
performance of a transformer mainly depends upon the flux linkages between these windings. For
efficient flux linking between these windings, one low reluctance magnetic path common to all
windings should be provided in the transformer. This low reluctance magnetic path in transformer
is known as core of transformer. In practice, the coils of the transformer possess resistance. So a
part of the energy is lost due to the heat produced in the resistance of the coil
CHAPTER-7
Core heating oven:
Three phase transformer losses will generate enough heat so that external cooling system must
be added. A closer look at these characteristics is necessary to better understand the thermal
aspects of power transformers in heating chamber we were placed core, aluminum, etc.
Transformer oil also placed in heating chamber.

Radiator Core Bake Ovens are batch process ovens designed to bond copper and brass radiators

and heat exchangers. The thermal process heats up the soldering flux applied to the cores

causing them to reflow, creating a secure bond between dissimilar metals

Radiator Core Bake Ovens are batch process ovens designed to bond copper and brass radiators
and heat exchangers. The thermal process heats up the soldering flux applied to the cores
causing them to reflow, creating a secure bond between dissimilar metals

Precautions:

Temperature Control: It is crucial to closely monitor and control the temperature during the core
heating process. The temperature should be set within the manufacturer's specified limits to
prevent overheating and potential damage.
Heating Duration: The duration of heating should be appropriate for the specific transformer and
core material. Following manufacturer guidelines or consulting with experts can help ensure that
the core is dried adequately without being subjected to excessive heat.

Uniform Heating: To avoid localized overheating or temperature gradients within the core, it is
essential to ensure uniform heat distribution during the drying process. This can be achieved
through proper oven design, positioning of the transformer within the oven, and using suitable heat
transfer methods.

Safety Measures: Core heating ovens should be operated with proper safety precautions.
including adequate ventilation, fire prevention measures, and adherence to electrical safety
standards.

Uniform Heating: To avoid localized overheating or temperature gradients within the core, it is
essential to ensure uniform heat distribution during the drying process. This can be achieved
through proper oven design, positioning of the transformer within the oven, and using suitable heat
transfer methods.

Advantages:
1. Improved Efficiency: The core helps in directing and concentrating the magnetic field
generated by the primary winding. This efficient magnetic coupling facilitates the transfer of
energy from the primary to the secondary winding, resulting in an improved overall efficiency of
the transformer.

2. Reduced Size and Weight: The presence of a core allows for a compact and lightweight
transformer design. The core material, often made of laminated iron or steel, provides a high
magnetic permeability, allowing for a higher magnetic flux density with smaller core dimensions.

3. Lower Magnetizing Current: The core reduces the magnetizing current required to establish
the magnetic field in the transformer. This lower magnetizing current reduces power losses and
improves the efficiency of the transformer.

4. Easier Cooling: The core provides a path for efficient heat dissipation. It allows for the
installation of cooling systems, such as cooling oil or forced air, to maintain optimal operating
temperatures and prevent overheating

Disadvantages:
1. Core Losses: The core material can exhibit hysteresis and eddy current losses, resulting in
power dissipation and reduced efficiency. These losses can be minimized by using high- quality
core materials and proper design techniques,
2. Cost: The addition of a core increases the cost of the transformer. Core materials, such as
highgrade silicon steel, can be expensive, especially for high-voltage and power transformers.

3. Complexity: The presence of a core adds complexity to the transformer design and
manufacturing process. The winding arrangements, insulation, and core assembly require careful
consideration to ensure proper functioning and reliability.
 CHAPTER-8

MEGGER TEST:
Insulation Resistance Test or Megger Test of Transformer Insulation
resistance is the ratio of applied voltage to the resulting current at a
specified time after the voltage is applied. Direct voltage is used for measuring insulation
resistance values Insulation resistance test of transformer is essential type test.

Purpose of megger test:

Megger test measures resistance between the phase windings of the motor under test and
ground. If there is an insulation breakdown, the resistance is negatively impacted and there is a
departure between phases or between one measurement and a previous one and a determination
of motor health is made

Process of megger test:

First we will disconnect all the line and neutral terminals of the transformer

Megger test leads are connected to LV and HV bushing studs to measure Insulation Resistance IR
value in between the LV and HV windings.

Megger test leads are connected to HV bushing studs and transformer tank earth point to measure
Insulation Resistance IR value in between the HV windings and earth. 3

Megger test leads are connected to LV bushing studs and transformer tank earth point to measure
Insulation Resistance IR value in between the LV windings and earth.

Advantages of megger test:

No external source required to operate.

Cheaper available in market

Proactive Equipment Condition Analysis Reduced Risk of Emergency Power System Failure

Insured Availability

Predictive Repairs

Asset Management

Predictive Equipment Life Expectancy

 CHAPTER-9

Winding:

It consist of paper-insulated, current carrying conductors wound around sections of the core a
winding lead is an insulated conductor that connects a winding to another winding, to a tap
changer, or to an exit terminal
Primary winding:

The winding which is connected to supply mains is known as primary winding Secondary

winding:

The winding which is connected to load is known as secondary winding

LV winding:

The winding which is connected to low voltage is known as low voltage (LV) winding

HV winding:

The winding which is connected to High voltage is known as high voltage (HV) winding.
 CHAPTER-10

Types of connection in transformer:

Star connection

Delta connection

Star connection:
one end of each phase line is connected to a common neutral point that may se ponnected to the
earth as protection against lightning or to a wire to which all the other neutral points of the system
are connected compare delta connection.

Delta connection:
It is designed to reduce the electromagnetic interference in devices connected to 3-phase delta
power The Delta configuration contains four wires, three hot conductors and one ground
conductor .
 CHAPTER-11

METERS

Ammeter
Voltmeter

Wattmeter

Multimeter

1. Ammeter:

It is an instrument used for measuring either direct (DC) or alternating (AC) electric
current, in amperes

2. voltmeter:

A voltmeter is an instrument used for measuring electric potential difference

between two points in an electric circuit. It is measured Voltage in volts.

3.wattmeter:

The wattmeter is a combination of an ammeter and a voltmeter. It measures both

voltage and current and determines the resultant power. Electric power is
measured using an instrument called a wattmeter

4. Multimeter:

Multimeter is a tester used to measure electrical voltage, current, resistance and

so on. Multimeters are mainly of two types, analog and digital. Both are used for
measuring and fault detection in electrical circuits.

5.Clamp meter:

Clamp meters allow electricians to bypass the old-school method of cutting into a
wire and inserting a meter's test leads into the circuit to take an in-line current
measurement. The jaws of a clamp meter do not need to touch a conductor during
a measurement.
CHAPTER-12
Types of bushings:

There are two types of bushings

• Solid or bulk type

• Capacitance graded or condenser type

Solid type bushing:

The solid-type bushing is also called bulk-type bushing. A solid-type bushing consists of an
insulator with a central conductor and electrical-grade mineral oil is filled between the insulato and
conductor. This increases the dielectric strength of the bushing

Condenser type bushing:

A bushing in which me- tallic or nonmetallic conducting layers are arranged within the insulating
material for the purpose of controlling the distribution of the electric field of the bushing, both
axially and radially by capacitive grading.

conductors through an earthed barrier such as a wall or a metal tank. It must provide
electrical insulation for the rated HV bushing:

A bushing is a device for carrying one or more high voltage voltage and for service over
voltages and also serve as mechanical support for the conductor and external
connections.
LV bushings :

The low-voltage bushing is located on the side used to connect the cabinet busbar to
the low voltage transformer coil. If the low- voltage bushing or sealing gasket is
damaged it may cause discharge or oil leakage and need to replace the low-voltage
bushing or gasket.

CHAPTER-13
Lightning arrestor:

A lightning arrester also called lightning isolator is a device, essentially an air

gap between an electric wire and ground, used on electric power transmission
and telecommunication systems to protect the insulation and conductors of the
system from the damaging effects of lightning. The typical lightning arrester has
a high- voltage terminal and a ground terminal. When a lightning surge travels
along the power line to the arrester, the current from the surge is diverted
through the arrester, in most cases to earth

Purpose of lightning arrestor:

Their purpose is to limit the rise in voltage when a communications or power line is struck by
lightning or is near to a lightning strike

Function of lightning arrestor:

Lightning arresters are devices that help prevent damage to apparatus due to high voltages

Advantages of lightning arrestor:

Property damage can be reduced from strokes of lighting Outdoor equipment of the substation can
be protected. Avoid damage in lines. Outlet surges can be avoided.

Electromagnetic interference.

Simple to use.

Disadvantages of lightning arrestor:

• It occupies more space.
• The installation cost is high.

CHAPTER-14
Crane:
A crane is a type of machine, generally equipped with a hoist rope, wire ropes or chains, and
sheaves, that can be used both to lift and lower materials and to move them horizontally. It is
mainly used for lifting heavy objects and transporting them to other places

Crane operating system:

Cranes, like all machines, obey the principle of conservation of energy. This means that the
energy delivered to the load cannot exceed the energy put into the machine. For example, if a
pulley system multiplies the applied force by ten, then the load moves only one tenth as far as the
applied force
 CHAPTER-15

Power analyser:

A power analyzer is an instrument that measures and quantifies the rate of power flow in electrical
systems. Power flow is expressed in Joules/second(J/s) or kilowatt-per-hour (kW/h) Electrical
power is the rate per unit of time that electrical energy is transferred in an electrical system
between two points. A power analyzer is an instrument that measures and quantifies the rate of
power flow in electrical systems. Power flow is expressed in Joules/second (J/s) or kilowatt-per-
hour (kW/h). Electrical power is the rate per unit of time that electrical energy is transferred in an
electrical system between two points.
 CHAPTER-16

Insulation paper:

Electrical insulation paper is used to insulate transformers and motors because pure cellulose has
outstanding electrical properties. During development, manufacturers of insulation paper need to
test their products in order to ensure a consistent level of quality Insulating paper is made up of
vegetable fibers that are felted together to form a sheet. The fibers are obtained from plants like
cotton, straw, hemp, manila, and coniferous trees. When this insulating paper is put into the
insulating oil under vacuum, it attains extremely high electric strength
Insulating tape:-

As the name itself says, insulating tape is used for various taping purposes. These are available in
a variety of forms like cotton tapes, woven tapes, glass woven tapes, and phenol laminated paper
base sheet. These tapes are used in areas where high strength is required. They are also used for
banding of transformer cores

Wood-based laminates:-

Wood-based laminates are made from selected veneers that are obtained from various timbers.
The veneers are first dried, and then are partially/completely saturated naturally. Such laminates
are used in areas that require higher mechanical and lower electric strength. They are used in
making a variety of components like coil clamping rings, cores, yokes, and supports
 CHAPTER-17

PAINTING:-

Purpose

1. Improve the electrical insulation performance of transformers (Insulation paint can improve
the electrical strength and insulation resistance of the product insulation system to improve its
electrical insulation performance and meet the electrical insulation performance requirements of
transformers).

2. Enhance the adaptability of the transformer to the environment (Insulating paint can
enhance the moisture resistance, mildew resistance, corrosion resistance, salt spray resistance,
UV resistance and other harmful substances of the transformer insulation system to enhance the
adaptability of the transformer to the environment.)

3. Enhance the mechanical strength of the transformer (Insulation paint can increase the
mechanical strength of the transformer and meet the requirements of vibration and shock during
transportation and use. At the same time, it can also reduce the noise caused by the
electromagnetic force during use),

4. can improve the thermal conductivity of the transformer (electronic transformer insulation
paint, the gap between the iron core and the winding is filled with paint film, which can improve its
overall thermal conductivity and reduce the temperature rise of the motor and transformer)

5. It improve the appearance of the transformer (after the transformer is impregnated with a
certain required insulating paint, the copper and iron so that the external light is exquisite and
powerful).
materials used by it can be reduced, Advantages:

1. excellent insulation performance,

2. good adhesion and high mechanical strength;

3. small shrinkage stress;

4. heat resistance should meet different requirements of the product;

5. outdoor or special environment should meet Its special requirements, such as anti-
radiation,anticorrosion, anti-ultraviolet, etc.

6. Flexible process, such as good operability, non-toxic or low toxicity, short drying time, high
flameretardant performance, etc.
 CHAPTER-18

THE PROCESS OF REPAIRING THE TRANSFORMERS:

1.Unloading the Transformers:

2.Dismantling the Transformers:
3.Draining out the oil:
4.Seperation of the core and windings:
5.1st Inspection of coils for weight and wire gauge:

6.Rewinding of HT & LT :
7.2ND Inspection of coils for weight and wire gauge:

8.Assembling:
9.Core and frame fitting:
10.Placing in Heating chamber:
11.Tanking:
12.Testing:
13.Painting:
14.Loading the Transformers:

CONCULSION

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.

The push towards modular designs not only streamlines manufacturing processes but also aligns
with the industry’s responsiveness to changing energ demands. The advent of 3D printing
technology introduces agility to the manufacturing ecosystem, fostering rapid prototyping and
customization whil minimizing material waste. In parallel, an emphasis on resilience and grid
integration underscores the importance of transformers in fortifying power